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Background report on best environmental management
practice in the fabricated metal product manufacturing sector
Study by VITO in collaboration with Sirris and
Agoria for the European Commission's Joint Research Centre
December 2015
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 2
Prepared by
VITO
Liesbet Van den Abeele
Toon Smets
An Derden
Caroline Polders
Sirris
Thomas Vandenhaute
Stefan Milis
Olivier Malek
Patrick Cosemans
Daan Dewulf
Andries Reymer
Sven De Troy
Agoria
Heidi Van Waes
Editors European Commission – Joint Research Centre
Paolo Canfora
Marco Dri
Ioannis Antonopoulos
Pierre Gaudillat
The information and views set out in this report are those of the authors and do not
necessarily reflect the official opinion of the Commission. The Commission does not
guarantee the accuracy of the data included in this study. Neither the Commission nor
any person action on the Commission’s behalf may hold responsible for the use which
may be made of the information contained therein.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 3
Background report on best environmental management
practice in the fabricated metal
product manufacturing sector
Study by VITO in collaboration with Sirris and Agoria for the European Commission's Joint
Research Centre
VITO: Liesbet Van den Abeele, Toon Smets, An Derden, Caroline Polders
Sirris: Thomas Vandenhaute, Stefan Milis, Tom Jacobs, Olivier Malek, Patrick
Cosemans, Daan Dewulf, Andries Reymer, Sven De Troy
Agoria: Heidi Van Waes
December 2015
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 4
Abstract
This document is a background report supporting the elaboration of a sectoral reference
document on best environmental management practice for the Manufacturing of Fabricated
Metal Products. It provides guidance on techniques, measures and actions which allow
organisations in the Fabricated Metal Products sector to minimize their impact on the
environment in all the aspects under their direct control (direct environmental aspects) or on
which they have a considerable influence (indirect environmental aspects).
This activity is part of the European Commission's Joint Research Centre (JRC) work on the
identification of best environmental management practices (BEMPs) and the development of
Sectoral Reference Documents under the EU Eco-Management and Audit Scheme (EMAS).
The document first describes proposed BEMPs for supporting processes, divided into BEMPs for
management, procurement and supply chain management (3) and for the optimization of
utilities (7). BEMPs on manufacturing processes are then described, divided into four process
groups: BEMPs for all manufacturing processes (4), for forming processes (3), for removing
processes (2), for finishing processes (2). Finally two BEMPs on concurrent engineering and
product design define how the environmental impact within the value chain of companies
manufacturing fabricated metal products can be minimized.
Résumé
Ce document est un rapport préliminaire servant de base à l'élaboration d'un document de
référence sectoriel sur les meilleures pratiques de management environnemental dans le
secteur de la fabrication de produits métalliques. Il fournit des conseils sur les techniques, les
mesures et actions qui permettent aux entreprises du secteur de réduire leur impact sur
l’environnement, pour tous les aspects qui se trouvent directement sous leur contrôle (aspects
environnementaux directs) ou pour les aspects sur lesquels elles ont une influence importante
(aspects environnementaux indirects).
Cette activité fait partie du travail du Centre Commun de Recherche de la Commission
Européenne (JRC) sur l’identification des meilleures pratiques de management environnemental
(MPME) et le développement des Documents de Référence Sectoriels dans le cadre du Système
européen de management environnemental et d'audit (EMAS).
Ce document décrit tout d'abord les propositions de MPMEs relatives aux procédés de support,
divisées en pratiques de gestion, d’approvisionnement et de gestion de la chaîne logistique (3)
et en pratiques pour l’optimisation des fournitures de services (7). Par la suite sont décrites les
MPMEs relatives aux procédés de fabrications, qui sont divisées en quatre groupes : les MPMEs
applicables à tous les procédés de fabrication (4), les MPMEs relatives aux procédés de formage
(3), les MPMEs relatives aux procédés de décapage (2) et les MPMEs relatives aux procédés de
finition (2). Les deux dernières meilleures pratiques, relatives à l'ingénierie simultanée
(concurrent engineering) et à la conception de produits définissent comment l’impact
environnemental le long de la chaîne de valeur des fabricants de produits métalliques peut être
minimisé.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 5
Executive summary
The European Commission's Joint Research Centre (JRC) is developing a sectoral
reference document on best environmental management practice for the Manufacture
of Fabricated Metal Products1. This will be a guidance document on techniques,
measures and actions, which allow organisations in the sector to minimise their impact
on the environment in all the aspects under their direct control (direct environmental
aspects) or on which they have a considerable influence (indirect environmental
aspects). This activity is part of the JRC's work on the identification of best
environmental management practices and the development of Sectoral Reference
Documents under the EU Eco-Management and Audit Scheme (EMAS). This brief
introduction outlines the proposed scope and priorities of the project and provides a
provisional list of proposed Best Environmental Management practices (BEMPs) for the
sector.
The work will cover the most relevant manufacturing and supporting activities and
processes of the Fabricated Metal Products sector, such as forming processes,
removing processes, additive and welding processes and finishing processes. The
primary manufacturing of iron, steel and non-ferrous metals is not included in the
scope of the document. For all activities and processes within the scope, BEMPs will be
identified both of a technical and/or technological nature, such as improving the
energy efficiency of a certain process, and of a more organisational or management
type, such as chemical leasing or engaging in environmental improvement with
suppliers. BEMPs will be identified not only within the physical site boundaries of
organisations belonging to the sector, but also looking at minimising environmental
impacts across the entire value chain. Besides BEMPs that improve the environmental
performance of the Fabricated Metal Products sector, BEMPs contributing to an
improvement of the environmental performance of other related sectors are also
considered (Figure 1). In particular, BEMPs on concurrent engineering and product
design define precisely how the environmental impacts within the value chain of
Fabricated Metal Product manufacturing companies can be minimised.
1 For more information, see http://susproc.jrc.ec.europa.eu/activities/emas/fab_metal_prod.html
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 6
Indirect aspectsDirect aspectsIndirect aspects
Product & Manufacturing Design
Supporting processes: Manufacturing Processes
Forming processes
Removing processes
Additive processes
Finishing processes
Logistics handling & storage
Utilities and maintenance
Emission treatment
Process design(Product Level)
Infrastructure design(Plant Level)
Manufacturing Processes
Assembly
Protections &
packaging
Otherprocesses
Market Processes
Use Phase
End of Life
Wasteprocessing
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Solid waste
Solid waste
Joining processes
Manufacturing Processes
Upstream activities
Raw Materials
Energy
Water
Concurrent engineering
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Product design
Management, procurement, supply chain management,
quality control
Figure 1. Schematic overview of the direct and indirect aspects and environmental
pressures of the Fabricated Metal Products sector
JRC contracted VITO, Sirris and Agoria to support the identification of the main
environmental issues for the sector, and put forward proposals of BEMPs and
environmental performance indicators. These proposals are summarised below and will
be the basis for discussion with stakeholders via the forum of a European Technical
Working Group (TWG) of sectoral experts to be established in Summer-Autumn 2016.
Expressions of interest to join the TWG can be sent
to JRC-IPTS-EMAS@ec.europa.eu.
Structure of the work and proposed BEMPs
The proposed BEMPs for supporting processes are divided into management,
procurement and supply chain management:
- Extend the lean principles with measures for energy and material
consumption describes an overall approach for reducing the amount of energy
and material used in Fabricated Metal Product manufacturing companies;
- By taking effective Measures for stock reduction – while keeping customer
demand flexibility, the lead time will be lower. This results not only in smaller
stock and less work in progress but also in less non-conforming products and a
lower environmental impact.
- Cross-sectoral and value chain collaboration (by communication and
integration) lead to a reduction of the environmental impact over the value
chain;
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 7
- By means of Chemical leasing & Chemical management services, Fabricated
Metal Products manufacturers can reduce the amount of waste generated, and
emission of chemicals used in the various manufacturing processes;
and BEMPs for optimisation of utilities within the Fabricated Metal Products
organisations:
- The BEMP on Energy management describes an overall approach for reducing
and optimising the energy use within the organisations of the sector. The five
following BEMPs specify how this can be achieved for the different utilities and
process lines;
- Efficient ventilation deals with the minimisation of the ventilation needs, as well
as with the optimisation of the ventilation system design and use;
- Optimal lighting adapted to the specific needs of the production line, storage
rooms, utility rooms, offices etc. results in better light quality, better working
conditions and a lower electricity consumption;
- Energy and water savings of cooling circuits deals with the systematic
approach of reducing the cooling needs, using and optimising the cooling design;
- Efficient use of compressed air systems by minimising pressurised air needs
and optimising the system’s design and use, results in a lower overall energy use;
- The implementation of smart tools (switches, software, PLC steering, etc.) on
machines results in a Reduction of standby energy of metal working
machines.
BEMPs on manufacturing processes are divided into four process groups. The following
BEMPs are applicable for all manufacturing processes:
- Application of solid low-friction coatings on tools and components and
Application of wear and corrosion-resistant coatings of tools and
equipment are two BEMPs where the surface of tools and equipment is changed.
The first BEMP results in a longer lifetime of the tools and a reduction of
lubricoolant use in the production process. The second one focuses on the
protection of the underlying materials from corrosive elements, resulting in longer
lifetime of tools and produced goods;
- There are two main trends in eco-efficient cooling for machining operations:
cryogenic cooling and Minimum Quantity Lubrication (MQL). The BEMP Selection
of coolant as environmental and performance criterion results in a significant
reduction of lubricant use.
BEMPs for forming processes:
- Incremental Sheet metal Forming (ISF) as alternative for mould making
leads to lower material use. The technique starts from metal sheets, which are
formed by punching;
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 8
- Additive manufacturing of complex equipment - flow optimization for
optimal heat transfer and temperature control gives a solution for shaping
complex metal pieces by using a limited amount of raw materials;
- Multi-directional forging: a resource efficient metal forming alternative for
complex geometric pieces in large series leads to lower material and energy use.
BEMPs for removing processes:
- Manufacturing processes that combine two or more established processes are
described in Hybrid machining as a method to reduce energy consumption;
- Machining of near-net-shape feedstock uses products which initial form is very
close to the final product’s geometry. This results in a reduction of the number of
finishing operations.
BEMPs for finishing processes:
- Reduce the energy for paint booth HVAC with predictive control is done by
monitoring the actual temperature and humidity of the incoming air in the paint
booth on the one hand and conditioning this air to the optimal window for curing
on the other hand. This results in a lower energy use by the HVAC unit;
- Selection and optimization of thermal processes for curing wet-chemical
coatings on metal products leads to lower energy use for curing. It comprises a
combination of choosing the optimal paintings and coatings and the optimal drying
technique (room curing, high temperature curing, IR or UV curing).
The two proposed BEMPs on concurrent engineering and product design provide
guidance on how the environmental impacts within the value chain of companies,
which belong to the manufacture of fabricated metal products, can be minimised:
- By dismantling products, which contain high value materials and pieces, the latter
can be reassembled into new products. The Remanufacturing of high value
components does not only have a positive impact in the Fabricated Metal
Products company itself, but also up- and downstream in the value chain;
- Co-design and open innovation with downstream partners to reduce
environmental impact during product life cycle leads to new products and
product designs. During the design phase, all aspects of the production, use and
reuse are taken into account.
Companies from the fabricated metal products sector interested in implementing best
practice in the improvement of environmental performance are recommended to refer
instead to the final Best Practice Report that will be available on-line2 as soon as it is
finalised and published.
2 The Best Practice Report will be available online at
http://susproc.jrc.ec.europa.eu/activities/emas/fab_metal_prod.html
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 9
Synthèse
Le Centre Commun de Recherche (JRC) de la Commission européenne établit un
document de référence sectoriel sur les meilleures pratiques de management
environnemental dans le secteur de la fabrication de produits métalliques. Ce
document fournira des conseils sur les techniques, les mesures et actions qui
permettent aux entreprises du secteur de réduire leur impact sur l’environnement,
pour tous les aspects qui se trouvent directement sous leur contrôle (aspects
environnementaux directs) ou pour les aspects sur lesquels elles ont une influence
importante (aspects environnementaux indirects). Cette activité fait partie du travail
du JRC sur l’identification des meilleures techniques de gestion de l'environnement et
le développement des Documents de Référence Sectoriels dans le cadre du Système
européen de management environnemental et d'audit (EMAS). Cette introduction
explique le cadre proposé et les priorités du projet. En outre, une liste des meilleurs
pratiques de gestion environnementale est présentée.
Le projet couvrira les principaux procédés de fabrication et de support du secteur FPM
tels que les procédés de formage, les procédés d’usinage, les procédés additifs et de
soudage, et les procédés de finition. Le document ne couvrira pas la fabrication de
base du fer, de l’acier et des métaux non ferreux.
Pour chaque activité et procédé relevant du champ d’application, les meilleurs
pratiques de management environnemental (MPMEs) seront identifiées, sur le plan
technique ou technologique, comme l’amélioration de l’efficience énergétique de
certains procédés, ou un mode amélioré de gestion ou d’organisation, tels que le
leasing de produits chimiques, ou les démarches d’amélioration auprès des
fournisseurs.
Les MPMEs seront identifiées non seulement à l’intérieur des limites physiques du site
des entreprises du secteur FPM, mais aussi en cherchant à réduire les impacts
environnementaux à travers l’intégralité de la chaine de valeur.
En plus des MPMEs qui améliorent les performances environnementales du secteur
FPM, les pratiques qui contribuent à améliorer les performances environnementales
d’autres secteurs seront aussi considérées (Error! Reference source not
found.Error! Reference source not found.).Plus spécifiquement les MPMEs
relatives à l’ingénierie simultanée et à la conception de produits définissent plus
précisément comment l’impact environnemental le long de la chaine de valeur peut
être réduit.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 10
Indirect aspectsDirect aspectsIndirect aspects
Product & Manufacturing Design
Supporting processes: Manufacturing Processes
Forming processes
Removing processes
Additive processes
Finishing processes
Logistics handling & storage
Utilities and maintenance
Emission treatment
Process design(Product Level)
Infrastructure design(Plant Level)
Manufacturing Processes
Assembly
Protections &
packaging
Otherprocesses
Market Processes
Use Phase
End of Life
Wasteprocessing
Aux
iliar
y em
issi
ons
Air
Em
issi
ons
Wat
er E
mis
sion
s
Solid waste
Solid waste
Joining processes
Manufacturing Processes
Upstream activities
Raw Materials
Energy
Water
Concurrent engineering
Aux
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Wat
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Product design
Management, procurement, supply chain management,
quality control
Figure 2. Aperçu schématique des aspects directs et indirects et des pressions
environnementales du secteur FPM
Le JRC a sous-traité à VITO, Sirris et Agoria la mission d'étayer l’identification des
aspects environnementaux du secteur et de proposer des MPMEs et des indicateurs de
performance. Ci-dessous, la liste proposée des MPMEs est présentée, qui formera la
base de la discussion avec les parties prenantes via le forum d’un groupe de travail
technique européen (GTT) des experts sectoriels, à établir entre l'été et l'automne
2016.
Les manifestations d’intérêt pour rejoindre le GTT peuvent être envoyées à
JRC-IPTS-EMAS@ec.europa.eu3
Les propositions de MPMEs relatives aux procédés de support sont divisées en
pratiques de gestion, d’approvisionnement et de gestion de la chaîne des fournisseurs:
- Etendre les principes de “flux tendu” aux mesures pour la
consommation d’énergie de matériaux décrit une approche globale pour
réduire la quantité d’énergie et de matériaux utilisés dans les entreprises FPM;
- En mettant en place des mesures pour la réduction des stocks – tout en
conservant la flexibilité face à la demande des clients, le délai de
livraison se réduira. Par conséquent, le stock sera plus faible et engendrera
moins de travail, mais aussi moins de produits non conformes et un impact
environnemental plus faible;
- La collaboration entre secteurs et à travers la chaîne de valeur
(communication et intégration) mène à une réduction de l’impact
environnemental le long de la chaîne de valeur;
- Au moyen de leasing de produits chimiques & de services de gestion
chimique, les entreprises FPM peuvent réduire les quantités de déchets
générés, et l’émission de produits chimiques utilisé dans leurs process.
Et les MPMEs pour l’optimisation des services utilitaires:
3 N.B. les discussions du GTT se font par défaut en anglais.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 11
- La MPME sur la gestion de l’énergie décrit une approche globale pour réduire
la consommation et l'utilisation d’énergie. Les six MPMEs suivantes spécifient
comment le mettre en œuvre pour différents services et lignes de
transformation;
- La ventilation efficace, en minimisant les besoins de ventilation et en
optimisant sa conception et son utilisation, a pour résultat de diminuer la
consommation énergétique globale;
- L’éclairage optimal, adapté aux besoins spécifiques des lignes de production,
des espaces de stockage, des zones utilitaires, des bureaux, etc. a pour
résultat une meilleure qualité de lumière, de meilleures conditions de travail et
une moindre utilisation de l’électricité;
- Une approche systématique pour réduire les besoins de refroidissement,
optimiser la conception des installations et leur utilisation mène à des
économies d’énergie et d’eau dans les circuits de refroidissement;
- L’utilisation efficace des systèmes d’air comprimé, en minimisant les
besoins d’air comprimé et en optimisant la conception et l’utilisation de
l’installation, a pour résultat de diminuer la consommation énergétique globale;
- La mise en place d’outils intelligents (commutateurs, logiciel, API, etc.) sur les
machines a pour résultat une réduction de l'énergie utilisée en mode
veille des machines de travail du métal.
Les MPMEs relatives aux procédés de fabrications sont divisées en quatre groupes. Les
MPMEs applicables à tous les procédés de fabrication:
- Revêtements solides à faible coefficient de friction et application de
revêtements résistants à l'usure et à la corrosion sur des outils et des
équipements sont deux MPMEs se rapportant à des procédés où la surface des
outils et des équipements est modifiée. La première MPME a comme résultat
d’augmenter la durée de vie des outils et de réduire l’utilisation d’agents
lubrifiants dans le procédé de production. La seconde augmente la durée de vie
des outils et des produits;
- Il existe deux tendances majeures pour le refroidissement éco-efficace des
opérations d’usinage : le refroidissement cryogénique et l’utilisation minimale
de la lubrification (Minimum Quantity Lubrication - MQL). La MPME sur la
sélection de fluides de refroidissement sur base de critères
environnementaux et de performance a pour résultat de réduire
totalement ou partiellement l’utilisation d’agents lubrifiants
Les MPMEs relatives aux procédés de formage:
- L’utilisation du formage incrémental (Incremental Sheet metal Forming
(ISF) comme alternative à la fabrication de moules mène à une
diminution de l’utilisation des matériaux. La technique utilise des feuilles de
métal qui sont formées par poinçonnage;
- La fabrication additive d’équipements complexes – optimisation des
flux pour un transfert de chaleur et un contrôle de température optimal
donne une solution de mise en forme des pièces métalliques complexes en
utilisant une quantité limitée de matières premières;
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 12
- Le forgeage multi-directionnel comme alternative efficace en ressource
au formage pour des pièces à la géométrie complexe en grandes séries mène
à réduire l’utilisation de matériaux et d’énergie.
Les MPMEs relatives aux procédés d’usinage:
- Les procédés de fabrication qui combinent deux procédés bien établis ou plus
sont décrits dans l’usinage hybride comme méthode pour réduire la
consommation d'énergie;
- L'usinage de pièces à forme quasi-définitive utilise des pièces brutes dont
la forme initiale est très proche de la géométrie du produit final. Il en résulte
une réduction du nombre des opérations de finition.
Et les MPMEs relatives aux procédés de finition:
- La réduction de l'utilisation d' énergie dans les cabines de peinture
avec contrôle CVC prédictif est réalisée d’une part, en enregistrant la
température réelle et l’humidité de l’air entrant dans la cabine de peinture, et
d’autre part, en conditionnant cet air de façon optimale pour la polymérisation,
ce qui résulte en une consommation moindre des installations de CVC.
- La sélection et l'optimisation des procédés thermiques pour le
durcissement des revêtements chimiques humides sur les produits
métalliques mène à une diminution de l’utilisation d’énergie. Cela comprend à
la fois la sélection optimale des peintures et revêtements et la sélection de la
technique optimale de séchage (température ambiante, haute température, IR
ou UV).
Deux MPMEs relatives à l'ingénierie simultanée (concurrent engineering) et à la
conception de produits définissent comment l’impact environnemental le long de la
chaîne de valeur des fabricants de produits métalliques peut être minimisé.
- En démontant les produits qui contiennent des matériaux et des pièces à haute
valeur ajoutée, ces derniers peuvent être réassemblés dans de nouveaux
produits. La remise à neuf des composés de grande valeur a un impact
positif non seulement sur les entreprises FPM mais aussi en aval de la chaîne
de valeur;
- Le co-design et l'innovation ouverte avec des partenaires en aval pour
réduire l'impact environnemental durant le cycle de vie du produit
mène à la conception de nouveaux produits. Durant la phase de conception,
tous les aspects de la production, de l’utilisation et de la réutilisation du produit
sont pris en compte.
Les entreprises du secteur intéressées par la mise en place de meilleures pratiques
pour améliorer leur performance environnementale devraient se référer au Rapport
final sur les Meilleures Pratiques qui sera disponible en ligne4 dès sa finalisation.
4 Le Rapport sur les Meilleures Pratiques sera disponible en ligne (en anglais) sur
http://susproc.jrc.ec.europa.eu/activities/emas/fab_metal_prod.html
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 13
Table of contents
Abstract ........................................................................................................... 4
Résumé ............................................................................................................ 4
Executive summary ........................................................................................... 5
Synthèse .......................................................................................................... 9
Table of contents ..............................................................................................13
List of figures ...................................................................................................15
List of tables ....................................................................................................18
List of acronyms ...............................................................................................20
Preface ............................................................................................................21
CHAPTER 1. General information on the Fabricated Metal Products sector and
definition of the scope .......................................................................................24
1.1. Composition of the Fabricated Metal Products sector .................................24
1.2. Economic relevance of the Fabricated Metal Product manufacturing sector ...28
1.3. Main environmental aspects and pressures of the Fabricated Metal Product
manufacturing sector .....................................................................................29 1.3.1. Environmental aspects ______________________________________________________________ 29
1.3.2. Environmental pressures and impacts ________________________________________________ 34
1.4. EMAS and the Fabricated Metal Product manufacturing sector ....................45
1.5. EU legislation, policy instruments and best practice guidance .....................46
1.6. Conclusions and Scope Best environmental management practice in the
Fabricated Metal Product manufacturing sector ..................................................84
CHAPTER 2. Best environmental management practice ......................................91
2.1. Technique portfolio ...............................................................................91
2.2. Best environmental management practices for the supporting processes .....97 2.2.1. Extend the lean principles with measures for energy and material consumption ___________ 98
2.2.2. Measures for stock reduction - while keeping customer demand flexibility _______________ 107
2.2.3. Cross-sectoral and value chain collaboration (by communication and integration) ________ 114
2.2.4. Chemical leasing & Chemical management services ___________________________________ 125
2.2.5. Energy management _______________________________________________________________ 132
2.2.6. Efficient ventilation ________________________________________________________________ 136
2.2.7. Optimal lighting ___________________________________________________________________ 145
2.2.8. Energy and water savings of cooling circuits __________________________________________ 154
2.2.9. Efficient use of compressed air systems ______________________________________________ 162
2.2.10. Reduction of standby energy of metal working machines ______________________________ 175
2.3. Best environmental management practices for the manufacturing processes
181 2.3.1. Application of solid low-friction coatings on tools and components ______________________ 182
2.3.2. Application of wear- and corrosion-resistant coatings of tools and equipment ____________ 188
2.3.3. Selection of coolant as environmental and performance criterion _______________________ 194
2.3.4. Incremental Sheet metal Forming (ISF) as alternative for mold making _________________ 206
2.3.5. Additive manufacturing of complex equipment - flow optimization for optimal heat transfer
and temperature control _____________________________________________________________________ 215
2.3.6. Multi-directional forging: a resource efficient metal forming alternative _________________ 222
2.3.7. Hybrid machining as a method to reduce energy consumption _________________________ 229
2.3.8. Machining of near-net-shape feedstock ______________________________________________ 235
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 14
2.3.9. Reduce the energy for paint booth HVAC with predictive control ________________________ 239
2.3.10. Selection and optimization of thermal processes for curing wet-chemical coatings on metal
products 245
2.4. Concurrent engineering and product design as Best environmental
management practice ................................................................................... 252 2.4.1. Remanufacturing of high value components __________________________________________ 252
2.4.2. Co-design and open innovation with downstream partners to reduce environmental impact
during product life cycle ______________________________________________________________________ 262
References............................................................ Error! Bookmark not defined.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 15
List of figures
Figure 1. Schematic overview of the direct and indirect aspects and environmental pressures of the
Fabricated Metal Products sector .......................................................................................................................... 6
Figure 2. Aperçu schématique des aspects directs et indirects et des pressions environnementales du
secteur FPM ............................................................................................................................................................ 10
Figure 3. Share of enterprise size classes (by number of persons employed) of total manufacturing (Division
C 10-33) and Fabricated Metal Product manufacturing (Division 25 and groups) (Eurostat, 2011) ....... 27
Figure 4. The 10 countries with the highest number of Fabricated Metal Products enterprises (NACE 25)
within the EU-28 (Eurostat, 2011) ..................................................................................................................... 28
Figure 5. Relative share of turnover for the NACE division 25 groups; total turnover equalled 472,000 million
euros (Eurostat, 2011) ......................................................................................................................................... 28
Figure 6. Organizational and temporal scale of environmental impact reduction approaches. Based on
Coulter et al. (1995) and Bras (1997). Red line: scope of this study .......................................................... 31
Figure 7. Schematic overview of the direct and indirect aspects and environmental pressures of the
Fabricated Metal Products sector ........................................................................................................................ 33
Figure 8. Relative share of direct and indirect emissions of the Fabricated Metal Products sector (EORA,
2011) ....................................................................................................................................................................... 42
Figure 9. Basis: Shankey diagram of steel flow – the activities of the Fabricated Metal Product
manufacturing sector are situated in the green area (Rolling and forming process) (Allwood, 2011);
black line: NACE 25; double red line: scope of this study .............................................................................. 43
Figure 10. Basis: Shankey diagram of aluminium flow – the activities of the Fabricated Metal Product
manufacturing sector are situated in the green area (Rolling and forming process). (Allwood, 2011)
black line: NACE 25; double red line: scope of this study .............................................................................. 44
Figure 11. Lean waste concept can be translated into energy terms and is strengthened by two additional
levers (http://www.mckinsey.com) .................................................................................................................... 99
Figure 12. Five-step process for implementing lean principles in a company (Lean Enterprise Institute, 2015)
................................................................................................................................................................................ 100
Figure 13. Principles of the Value Stream Method (Franhofer, 2011) .................................................................. 102
Figure 14: Energy Value Stream Analysis is similar representation as classic VSM visualisation (Fraunhofer,
2011) ..................................................................................................................................................................... 103
Figure 15. Production of a front bumper made of 5 parts in 4 production steps – calculation of energy
intensity demonstrates effect of product related approach (Fraunhofer, 2011) ....................................... 103
Figure 16. Example Value Stream Map shows a value stream map from a value and energy stream (EPA,
2011) ..................................................................................................................................................................... 104
Figure 17. Scheme of a traditional organization of the shop floor (Teim, 2010) ............................................... 108
Figure 18. Organization of the shop floor: before: traditional functional layout; after: cellular layout (Teim,
2010) ..................................................................................................................................................................... 108
Figure 19. Evolution of the energy use (kWh) per added value after implementing a QRM at Provan (Sirris,
Provan, 2015) ...................................................................................................................................................... 111
Figure 20. Representation of Industrial Ecology processes (GPEM, 2015).......................................................... 115
Figure 21. The Brainform re-use program (Brainform, 2015) ............................................................................... 117
Figure 22: DENSO filtercake (NISP, 2012) ............................................................................................................... 119
Figure 23: Oily grinding cake (NISP, 2009) ............................................................................................................. 119
Figure 24: Agfa’s old scrap flow (Pellegroms, 2015) .............................................................................................. 120
Figure 25: Agfa’s new scrap flow (Pellegroms, 2015) ............................................................................................ 120
Figure 26: Carbon footprint Agfa (Verschave, 2012) .............................................................................................. 121
Figure 27. ChL business model compared to the conventional business model (Dow Safechem 2015) ........ 126
Figure 28. Case study illustrating the potential of ChL (The Guardian, 2014, based on data from Ecolab,
Stockmeier, Johnson). ........................................................................................................................................ 128
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Figure 29. Fan Law: at 50% reduction of air-flow (which is achieved by automatically closing gates on non-
operating machinery), fan motor will consume only 12.5% of electricity of what is required when
suction is running at all workstations. This is a reduction of 87,5% (Litomisky, 2006) .......................... 139
Figure 30: Left: Unregulated system with duct system directly connected to dust collector, fan-motor
combination. Right: On demand system with sensors to close duct gates. VFD controlled fan motor
controlled by PLC (Litomisky, 2006) ................................................................................................................ 140
Figure 31. Savings by on-demand ventilations (Litomisky, 2006) ....................................................................... 142
Figure 32. Plant and heat pump load (Heemer et al, 2011) .................................................................................. 155
Figure 33. Hybrid systems offers different operation mode: for dry, adiabatic and wet-dry cooling (Baltimore
Aircoil, 2015) ........................................................................................................................................................ 158
Figure 34. Cost comparison between hybrid cooling towers and conventional wet cooling systems. The
comparison is based on a cooling load of 2 030 KW, an inlet temperature of 40°C, an outlet
temperature of 30°C and a wet bulb temperature of 274°C (Seneviratne M., 2007 ; based on data of
Balimore Aircoil) .................................................................................................................................................. 159
Figure 35: Potential saving related to compressed air (Ceati, 2007) .................................................................. 170
Figure 36: Energy management in a CNC controller (Heidenhain, 2010) ........................................................... 176
Figure 37: Power requirement for roughing (top) and finishing (bottom) milling of the housing (Heidenhain,
2010) ..................................................................................................................................................................... 177
Figure 38: Machine power requirement .................................................................................................................... 178
Figure 39: Energy profile for a CO2 laser (Kellens et al. 2013) ............................................................................. 178
Figure 40. Comparison of frictional performance; BALINIT is a solid low-friction coating (Oerlikon Balzers,
2010) ..................................................................................................................................................................... 183
Figure 41. Solid low-friction coating (BALINIT C) in dry running and starved lubrication (gear test) (Oerlikon
Balzers, 2010) ...................................................................................................................................................... 184
Figure 42. Machining cost and impact of a 20% increased cutting speed with high quality tools (Sandvik,
2008) ..................................................................................................................................................................... 190
Figure 43. Metal working fluid (MWF) costs in metal machining (DGUV, 2010) ................................................ 194
Figure 44. Cryogenic cooling solution on milling tool (Composite machining, 2014) ........................................ 195
Figure 45. Tool lifetime in turning with Liquid Nitrogen Coolant (LIN) compared to Dry and Regular Cooling
(AMT, 2015) ......................................................................................................................................................... 195
Figure 46. Wet and MQL cooling (Guhring, 2013) ................................................................................................... 196
Figure 47. Comparison of flows in conventional and cryogenic machining (Pušavec and Kopač, 2011) ....... 197
Figure 48. Comparison of cost per part (Pušavec and Kopač, 2011) ................................................................... 199
Figure 49. External and internal lubrication feed (DGUV, 2010) .......................................................................... 200
Figure 50. Saving potential for MQL (Guhring, 2013) ............................................................................................. 203
Figure 51. Process principle of incremental sheet forming, ISF (ISF-Light, 2012) ............................................ 207
Figure 52. Incremental sheet metal forming installation (INMA, 2014) .............................................................. 207
Figure 53. Platforms used for ISF, from left to right: CNC milling machine, industrial robot, dedicated
machine (Aminio, 2015) ..................................................................................................................................... 208
Figure 54. Current and potential fields of application of incremental sheet forming (Ames, 2008) ............... 210
Figure 55. Supporting tool in the background of the mold for a bothtub (Nordic Industrial Fund, 2003) ..... 210
Figure 56. Dimensions of the piece used in this economical calculation (Lamminen et al, 2003) .................. 211
Figure 57. Cost comparison diagram for incremental forming and deep drawing ............................................. 212
Figure 58: Schematic view of layer by layer build up in additive manufacturing process ................................ 215
Figure 59. Hydrauvision heat exchanger ‘Impossible-crossing’ (Compolight, 2015) ........................................ 216
Figure 60. Component that connects cooling circuits ............................................................................................. 218
Figure 61. Burner component from for Diametal ..................................................................................................... 218
Figure 62. Injection mold insert with optimal cooling channels ............................................................................ 218
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Figure 63. Left: conventional burner consisting of over 20 parts, right: new AM burner made by AM out of
one single piece ................................................................................................................................................... 219
Figure 64. Significantly lower burr percentage: The multi-directionally forged crankshaft (right) compared
with a conventionally forged one (IPH-Hannover, 2014) ............................................................................. 222
Figure 65. Examples of components that can benefit from burr free and multidirectional forging (Hatebur,
2015) ..................................................................................................................................................................... 223
Figure 66. Example of a burr free multi-directional forging sequence of a complex steel part (eg. crankshaft)
(IPH-Hannover, 2015) ........................................................................................................................................ 224
Figure 67. Workpiece stages during the five forging steps that are needed for the finished crankshaft. The
fourth step takes place with the multidirectional tool (IPH-Hannover, 2014) .......................................... 225
Figure 68. The adapted forging tools and the associated material flow in the burr free forging concept (b)
leads to significant reduction or elimination of burr formation in comparison with the traditional set-up
(a) (c) (IPH-Hannover, 2015) ........................................................................................................................... 225
Figure 69. CAD model of a multi-directional forging tool for the forging of a crankshaft. The arrows indicate
the multiple directions of moving tool parts (IPH-Hannover, 2015) ........................................................... 226
Figure 70. Example of a multi-directional forging tool. It not only presses metal into the form from above
but also at the same time from the sides. (IPH-Hannover, 2014). ............................................................ 226
Figure 71: Electrical Energy Requirement for different processes (Gutowski et al., 2006) ............................. 229
Figure 72: Hybrid process classification (Zhu et Al. 2013) .................................................................................... 230
Figure 73: Hybrid micro Milling/EDM machine (WZL, RWTH Aachen).................................................................. 232
Figure 74: Conventional Machining vs Laser Assisted Machining (LAM) (Anderson et Al. 2006) .................... 233
Figure 75: Near net shape machining (Whitesell group, 2015) ............................................................................ 235
Figure 76: Flowchart of MIM (Afraz, 2012)............................................................................................................... 236
Figure 77: Cold forming as a near net shape technology to allow less material waste, lower cost and lower
lead times (Whitesell group, 2015) .................................................................................................................. 237
Figure 78. Control window versus control point (Taikisha-group, 2015) ............................................................ 239
Figure 79. Situation before: situation of the paint booth with feedback control, Situation after: situation of
the paint booth with forward and feedback control (Toyota motor manufacturing, 2015 –Personal
communication at the Agoria event on automotive) ..................................................................................... 240
Figure 80. Reduction of CO2 and VOC by the use of water based paint and forward control of the HVAC of
the paint booth, comparing to conventional oil based paint and conventional drying technology
(Automotive manufacturing solutions, 2015) ................................................................................................. 242
Figure 81. Differences between a conventional UV lamp and a UV led for curing (UV process, 2015) .......... 247
Figure 82. Ecological fingerprint of six refinish primers (Wall et al., 2004) ........................................................ 247
Figure 83. Remanufacturing, restoring used products to useful life (CRR, 2013) ............................................. 252
Figure 84. The RemPro-matrix showing the relationship between the preferable product properties and the
generic remanufacturing process steps (Sundin, 2004) ............................................................................... 253
Figure 85. BMA assembly – disassembly line (BMA-ergonomics, 2015) ............................................................. 254
Figure 86. Steel waiting for a buyer at the Portal Power plant (Allwood, J.M. et al, 2012 and Portal Power,
2015) ..................................................................................................................................................................... 256
Figure 87. Rype Office offering (Rype Office, 2015) ............................................................................................... 257
Figure 88: Remanufacturing requires different aspects in the “three basic components of industry” to be
balanced (Sirris/Agoria, 2015) .......................................................................................................................... 259
Figure 89. Impact of full remanufacturing on EBITDA and jobs in four sectors in the UK (Lavery et al, 2013)
................................................................................................................................................................................ 259
Figure 90. Closed vs. open innovation (Chesbrough, 2003) .................................................................................. 262
Figure 91. The ConX® System (Cradle to Cradle Certified Products Registry, 2014)....................................... 265
Figure 92: Curana’s turnover and profit in relation to the bicycle production (Bosch, 2010).......................... 267
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List of tables
Table 1. Overview of the NACE division 25 (Rev.2) groups and classes ............................................................... 24
Table 2. Number of enterprises in the Fabricated Metal Product manufacturing sector (NACE Rev.2 division
25 and groups) (Eurostat, 2011) ........................................................................................................................ 26
Table 3. Economic indicators of the EU-28 Fabricated Metal Product manufacturing sector (Eurostat, 2011)29
Table 4. Influence on indirect environmental pressures by companies in the Fabricated Metal Products sector
(NACE 25) ............................................................................................................................................................... 35
Table 5. Assessment of the environmental pressures of the direct aspects (NACE 25) and interface
processes of the indirect aspects ........................................................................................................................ 36
Table 6. Comparison of sector classification systems of EORA (UK) and NACE Rev.2 ........................................ 39
Table 7. Direct and total emissions and resource use of the Fabricated Metal Products (sub) sectors
(Eurostat and EORA, 2011) ................................................................................................................................. 41
Table 8. Overview of EMAS registrations (registration numbers and organisations) in EU-28 in the Fabricated
Metal Products sector (http://ec.europa.eu/environment/emas/register/) ..... Error! Bookmark not defined.
Table 9. Global overview of processes/activities/techniques within the scope of BREFs (directly or indirectly)
linked to the manufacture of Fabricated Metal Products ................................................................................ 48
Table 10. Examples of direct environmental parameters covered in the BREFs (directly or indirectly) linked
to the manufacture of Fabricated Metal Products ............................................................................................ 58
Table 11. Overview of the EU legislation, policy instruments and best practice guidance relevant for products
and processes of the NACE 25 (sub)sectors ..................................................................................................... 59
Table 12. Overview of the policy instruments relevant for products and processes of the NACE 25
(sub)sectors ............................................................................................................................................................ 71
Table 13. Overview of the best practice guidance relevant for products and processes of the NACE 25
(sub)sectors ............................................................................................................................................................ 74
Table 14. Most relevant direct environmental aspects for the Fabricated Metal Products companies how
these are addressed .............................................................................................................................................. 92
Table 15. Most relevant indirect environmental aspects for the Fabricated Metal Products companies how
these are addressed .............................................................................................................................................. 95
Table 16. Panimpex results of QRM implementation (Sirris, 2014) ...................................................................... 111
Table 17. Energy management matrix ...................................................................................................................... 133
Table 18. Different type of cooling towers and their advantages and disadvantages, (based on Baltimore
Aircoil, 2015; Seattle Public Utilities, 2015; US Department of Energy, 2011) ........................................ 155
Table 19. Overview of the most common types of inappropriate use of compressed air in the Fabricated
Metal Products Sector ......................................................................................................................................... 163
Table 20. Overview of the main measures related to compressed air system configuration ........................... 165
Table 21. Sequence of steps that can be used to optimize the settings of compressed air systems ............. 166
Table 22. Considerations for optimal maintenance of compressed air systems ................................................. 167
Table 23. Examples of achievable energy saving through compressed air measures in an industrial context
(Carbon Trust, 2012) .......................................................................................................................................... 169
Table 24. Overview of auxiliary processes during standby mode (Duflou et al., 2011) ................................... 175
Table 25. Energy savings for several machines, comparison standby and shut down (Kellens et al., 2013) 179
Table 26. Advantages and disadvantages of applying solid low-friction coatings .............................................. 182
Table 27. Application of surface treatment processes (Oerlikon Blazers, 2010) ................................................ 189
Table 28. Machining cost and impact of a 20% increased cutting speed with high quality tools (Sandvik,
2008) ..................................................................................................................................................................... 191
Table 29. Examples of longer mold lifetime by using wear resistance coatings for the production of synthetic
materials (FME CWM, 2005) .............................................................................................................................. 191
Table 30. Comparison of the LCA of emulsion and cryogenic cooling (Pušavec and Kopač, 2011) ................ 198
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Table 31. Advantages and disafvantages of external and internal feed of MQL (DGUV, 2010) ...................... 200
Table 32. Areas of application for minimum quantity lubrication and dry processing (DGUV, 2010) ............ 201
Table 33. Examples of areas of minimum quantity lubrication application with production processes and
motivation (DGUV, 2010) ................................................................................................................................... 202
Table 34. Comparison of deep drawing and incremental sheet forming parameters and unit costs (Lamminen
et al, 2003) ........................................................................................................................................................... 212
Table 35. Examples of hybrid machining processes (Fraunhofer, 2014) ............................................................. 230
Table 36. A comparison of the toxicity & other properties of UV-curable ink components and some
commonly used ink solvents (PNEAC) ............................................................................................................. 248
Table 37. Total industrial installation and utility source emissions (metric tons/billion cans) (Golden, 2005)
................................................................................................................................................................................ 249
Table 38. Total industrial installation and utility energy use (million BTU/billion cans) (Golden, 2005) ....... 249
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List of acronyms
BAT Best available technique
B2B Business to business
BEMP Best environmental management practice
BREF BAT Reference Document
BREF ENE BAT Reference Document on Energy Efficiency
BREF FMP BAT Reference Document on Ferrous Metals Processing Industry
BREF ICS BAT Reference Document on Industrial Cooling Systems
BREF LCP BAT Reference Document on Large Combustion Plants
BREF NFM BAT Reference Document on Non Ferrous Metals Industries
BREF STM BAT Reference Document on Surface Treatment of Metals and Plastics
BREF STS BAT Reference Document on Surface Treatment using Organic Solvents
BREF WT BAT Reference Document on Waste Treatment Industries
CE Concurrent Engineering
ECDM Environmentally Conscious Design and Manufacturing
EDM Electrical Discharge Machining
EMAS Eco-Management and Audit Scheme
GHG greenhouse gases
HVAC heating, ventilating, and air conditioning
LCA Life Cycle Analysis
NMVOS non-methane volatile organic compounds
VFD Variable Frequency Drive
WEEE Waste electrical and electronic equipment
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Preface
This background report provides an overview of techniques that may be considered
Best Environmental Management Practices (BEMPs) in the manufacture of
fabricated metal products sector. The document was developed by VITO under a
contract with the European Commission's Joint Research Centre (JRC) on the basis of
desk research, interviews with experts and site visits. This background report is
intended to provide a preliminary basis for further discussions between the JRC and
technical experts via the forum of a Technical Working Group (TWG). The contents
of this report therefore represent early findings that will be further developed
through discussions with the TWG, according to a structured process outlined in
the guidelines on the “Development of the EMAS Sectoral Reference Documents on
Best Environmental Management Practice” (European Commission, 2014), which are
available online5.
The final findings will be presented in a best practice report produced by the JRC and
used for the development of an EMAS Sectoral Reference Document (SRD), as
illustrated below.
Source: JRC
Figure I: The present background report in the overall development of the Sectoral
Reference Document (SRD)
EMAS (the EU Eco-Management and Audit Scheme) is a management tool for
companies and other organisations to evaluate, report and improve their
environmental performance. To support this aim, and according to the provisions of
Art. 46 of the EMAS Regulation (EC No. 1221/2009), the European Commission is
producing SRDs to provide information and guidance on BEMPs in several priority
sectors, including the manufacture of fabricated metal products.
5 http://susproc.jrc.ec.europa.eu/activities/emas/documents/DevelopmentSRD.pdf
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Nevertheless, it is important to note that the guidance on BEMP is not only for EMAS
participants, but rather it is intended to be a useful reference document for any
relevant company that wishes to improve its environmental performance or any actor
involved in promoting best environmental performance.
BEMPs encompass techniques, measures or actions that can be taken to minimize
environmental impacts. These can include technologies (such as more efficient
machinery) and organisational practices (such as staff training).
An important aspect of the BEMPs proposed in this document is that they are proven
and practical, i.e.:
(1) They have been implemented at full scale by several companies (or by at least
one company if replicable/applicable by others);
(2) They are technically feasible and economically viable.
In other words, BEMPs are demonstrated practices that have the potential to be taken
up on a wide scale in the sector of fabricated metal products, yet at the same time are
expected to result in exceptional environmental performance compared to current
mainstream practices.
A standard structure is used to outline the information concerning each BEMP, as
shown in Table I.
Table I: Information gathered for each BEMP
Category Type of information included
Description Brief technical description of the BEMP including some
background and details on how it is implemented.
Achieved
environmental
benefits
Main potential environmental benefits to be gained through
implementing the BEMP.
Environmental
indicators
Indicators and/or metrics used to monitor the implementation
of the BEMP and its environmental benefits.
Cross-media effects Potential negative impacts on other environmental pressures
arising as side effects of implementing the BEMP.
Operational data Operational data that can help understand the implementation
of a BEMP, including any issues experienced. This includes
actual and plant-specific performance data where possible.
Applicability Indication of the type of plants or processes in which the
technique may or may not be applied, as well as constraints
to implementation in certain cases.
Economics Information on costs (investment and operating) and any
possible savings (e.g. reduced raw material or energy
consumption, waste charges, etc.).
Driving force for
implementation
Factors that have driven or stimulated the implementation of
the technique to date.
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Category Type of information included
Reference
organisations
Examples of organisations that have successfully implemented
the BEMP.
Reference literature Literature or other reference material cited in the information
for each BEMP.
Sector-specific Environmental Performance Indicators and Benchmarks of Excellence
are also derived from the BEMPs. These aim to provide organisations with guidance on
appropriate metrics and levels of ambition when implementing the BEMPs described.
Environmental Performance Indicators represent the metrics that are employed by
organisations in the sector to monitor either the implementation of the BEMPs
described or, when possible, directly their environmental performance.
Benchmarks of Excellence represent the highest environmental standards that have
been achieved by companies implementing each related BEMP. These aim to allow
all actors in the sector to understand the potential for environmental improvement
at the process level. Benchmarks of excellence are not targets for all organisations
to reach but rather a measure of what is possible to achieve (under stated
conditions) that companies can use to set priorities for action in the framework of
continuous improvement of environmental performance.
Conclusions on sector-specific Environmental Performance Indicators and Benchmarks
of Excellence are drawn by the TWG at the end of its interaction with the JRC.
Therefore the proposals for indicators (and, eventually, for benchmarks) contained in
this background report are to be considered no more than preliminary proposals from
the authors of this background report.
Role and purpose of this document
The present background report provides a basis to be used by the JRC and Technical
Working Group for the elaboration of the "JRC Scientific and Policy Report on Best
Environmental Management for the fabricated metal products sector", or simply "Best
Practice Report", containing the technical basis for the Sectoral Reference Document
(SRD).
Companies from the fabricated metal products sector interested in implementing best
practice in the improvement of environmental performance are recommended to refer
instead to the final Best Practice Report that will be available on-line6 as soon as it is
finalised and published.
6 The Best Practice Report will be available online at
http://susproc.jrc.ec.europa.eu/activities/emas/fab_metal_prod.html
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CHAPTER 1. General information on the Fabricated Metal Products sector and definition of the scope
1.1. Composition of the Fabricated Metal Products sector
NACE Rev. 2 Division 25
The industrial sector investigated in this study is the Manufacture of Fabricated
Metal Products, except machinery and equipment in the EU-28. Throughout the
document, the sector will be referred to under that name, "Fabricated metal product
manufacturing", "Metal fabrication", "the Fabricated Metal Products sector" or simply
(unless otherwise specified) "the sector".
This sector is covered by NACE Rev. 2 Division 25. The division 25 includes the
manufacture of products made solely from metal (such as parts, containers and
structures), usually with a static, immovable function; these can be contrasted with
combinations or assemblies of such metal products (sometimes with other materials)
into more complex units that — unless they are purely electrical, electronic or optical
— work with moving parts and are classified to Divisions 26 to 30. The NACE division
25 is composed of eight groups and further subdivided in classes (Table 1).
Table 1. Overview of the NACE division 25 (Rev.2) groups and classes
NACE code Description
C MANUFACTURING
25 Manufacture of fabricated metal products, except machinery and
equipment
25.1 Manufacture of structural metal products
25.11 Manufacture of metal structures and parts of structures
25.12 Manufacture of doors and windows of metal
25.2 Manufacture of tanks, reservoirs and containers of metal
25.21 Manufacture of central heating radiators and boilers
25.29 Manufacture of other tanks, reservoirs and containers of metal
25.3 Manufacture of steam generators, except central heating hot water
boilers
25.30 Manufacture of steam generators, except central heating hot water
boiler
25.4 Manufacture of weapons and ammunition
25.40 Manufacture of weapons and ammunition
25.5 Forging, pressing, stamping and roll-forming of metal; powder
metallurgy
25.50 Forging, pressing, stamping and roll-forming of metal; powder
metallurgy
25.6 Treatment and coating of metals; machining
25.61 Treatment and coating of metals
25.62 Machining
25.7 Manufacture of cutlery, tools and general hardware
25.71 Manufacture of cutlery
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NACE code Description
25.72 Manufacture of locks and hinges
25.73 Manufacture of tools
25.9 Manufacture of other fabricated metal products
25.91 Manufacture of steel drums and similar containers
25.92 Manufacture of light metal packaging
25.93 Manufacture of wire products, chain and springs
25.94 Manufacture of fasteners and screw machine products
25.99 Manufacture of other fabricated metal products n.e.c.
NACE codes 25.5 (Forging, pressing, stamping and roll-forming of metal; powder
metallurgy) and NACE code 25.6 (Treatment and coating of metals; machining) are
focusing on the core activities / processes of the sector. Almost all Fabricated Metal
Products companies use one or more of these activities in their production process.
The other NACE codes (25.1 till 25.4 and 25.7 and 25.9) describe typical products
made in the sector.
Structural metal products include, e.g., metal frameworks or parts for construction.
Steam generators include, e.g., generators for nuclear reactors or for power boilers.
The manufacture of weapons and ammunition includes the manufacture of heavy
weapons, small arms, air or gas guns and pistols, war ammunition, hunting, sporting
or protective firearms and ammunition, explosive devices such as bombs, mines and
torpedoes. Forging, pressing, stamping and roll-forming of metal and powder
metallurgy as well as the treatment and coating of metals and machining are typically
carried out on a fee or contract basis. The treatment and coating of metals also
includes plating, engraving, boring, turning, milling, sharpening, polishing and
welding. The manufacture of other fabricated metal products includes the production
of steel drums, containers, light metal packaging, nails, screws, bolts, nuts, springs,
chains, as well as household and industrial fixtures.
Depending on the type of product and the business model of companies, they will
produce end products for consumers or other companies (B2B); or they produce semi-
finished products (B2B). Below we give some examples of possible value chains.
Fabricated Metal Product manufacturing sector as supplier of semi-finished products:
- Sector company A produces metal tanks and reservoirs (NACE 25.29), which
will be used by a producer of small combustion plants, tank infrastructure;
- Sector company B produces metal structures (NACE 25.11), which will be used
by building companies to produce (pre)fabricated concrete elements;
- Sector company C produces locks and hinges (NACE 25.72), which will be used
by Sector company D for the manufacture of doors and windows (NACE 25.12).
Fabricated Metal Product manufacturing sector as supplier of end-products:
- Sector company E produces radiators (NACE 25.21) for consumers;
- Sector company F produces canes (NACE 25.92) for production of beverages
(NACE 11).
In the economic analysis we focus on the division 25. Excluded from this division 25
are the manufacture of tanks and other fighting vehicles (included as part of the
manufacture of other transport equipment, Division 30), the manufacture of metal
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December 2015 26
furniture (which is part of furniture manufacturing, Division 31), metal sports goods,
games and toys (which are classified to other manufacturing, Division 32) and
specialized repair, maintenance and installation activities, which form part of
Division 33 (Eurostat, 2013).
Number and size of Fabricated Metal Products enterprises
The Fabricated Metal Product manufacturing sector within the EU-28 comprised
390 966 enterprises in 2011. This represents 19% of the total number of
enterprises of the manufacturing (Section C) NACE divisions. The data of 2011 is
presented in this report. Although more recent data is available (i.e. 2013), the 2011
data appeared to be more complete throughout the various parameters analysed.
Furthermore, the trends and distribution of data in 2011 does not significantly differ
from the data of 2013.
Treatment and coating of metals; machining (Group 25.6) and Manufacture of
structural metal products (Group 25.1) are the groups with the highest number of
enterprises in the sector, followed by Manufacture of cutlery, tools and general
hardware (Group 25.7) and Manufacture of other fabricated metal products (Group
25.9). The Manufacture of steam generators, except central heating hot water boilers
(Group 25.3) and Manufacture of weapons and ammunition (Group 25.4) have the
smallest share in terms of number of enterprises (Table 2).
Table 2. Number of enterprises in the Fabricated Metal Product manufacturing sector
(NACE Rev.2 division 25 and groups) (Eurostat, 2011)
NACE Rev.2 Number of
enterprises
Share of sector
(division 25) (%)
Manufacture of fabricated metal products, except
machinery and equipment (Division 25)
390 966 100
Manufacture of structural metal products (Group 25.1) 122 050 31
Manufacture of tanks, reservoirs and containers of metal
(Group 25.2)
5 507 1
Manufacture of steam generators (Group 25.3) 1 017 0
Manufacture of weapons and ammunition (Group 25.4) 1 277 0
Forging, pressing, stamping and roll-forming of metal
and powder metallurgy (Group 25.5)
15 000 4
Treatment and coating of metals and machining
(Group 25.6)
142 879 37
Manufacture of cutlery, tools and general hardware
(Group 25.7)
52 300 13
Manufacture of other fabricated metal products
(Group 25.9)
51 000 13
The sector is characterized by the large number of small and medium-sized
enterprises (SMEs). In the Eurostat structural business statistics, size classes are
generally defined by the number of persons employed. The following division of size
classes is used:
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December 2015 27
(1) SMEs, with 1 to 249 persons employed:
o (a) micro enterprises: with less than 10 persons employed;
o (b) small enterprises: with 10 to 49 persons employed;
o (c) medium-sized enterprises: with 50 to 249 persons employed;
(2) Large enterprises, with 250 or more persons employed.
According to this definition, only 0.3% of the Fabricated Metal Products enterprises in
the EU-28 are categorized as large enterprises (2011). The largest share of
enterprises (82%) has less than 10 persons employed. Apart from some small
variations, the relative share of each size class is quite similar between the groups of
NACE division 25 (Figure 3).
Figure 3. Share of enterprise size classes (by number of persons employed) of total
manufacturing (Division C 10-33) and Fabricated Metal Product manufacturing
(Division 25 and groups) (Eurostat, 2011)
Geographical distribution
In the EU-28, Italy has the highest number of Fabricated Metal Products enterprises
(71 971; 18%), followed by Czech Republic (11%), Germany (11%), Spain (10%) and
Poland (8%) (Eurostat, 2011) (Figure 4).
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Figure 4. The 10 countries with the highest number of Fabricated Metal Products
enterprises (NACE 25) within the EU-28 (Eurostat, 2011)
1.2. Economic relevance of the Fabricated Metal Product
manufacturing sector
In 2011 the total turnover of the EU-28 Fabricated Metal Product manufacturing sector
accounted for 472 000 million euros, representing 7% of the turnover of total
manufacturing (division 10-33). The turnover significantly differs between the NACE
25 groups, with the manufacture of structural metal products (Group 25.1) having the
highest turnover (26%) followed by the treatment and coating of metals; machining
(Group 25.6, 23%) and the manufacture of other fabricated metal products (Group
25.9, 20%) (Figure 5).
Figure 5. Relative share of turnover for the NACE division 25 groups; total turnover
equalled 472,000 million euros (Eurostat, 2011)
Important economic indicators of the sector (turnover, added value at factor cost and
the number of employees) and their distribution within the EU-28 are given in Table 3.
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December 2015 29
Table 3. Economic indicators of the EU-28 Fabricated Metal Product manufacturing
sector (Eurostat, 2011)
region/country Turnover Value added at factor
cost
Number of
employees
Value
(million €)
Share
(%)
Value
(million €)
Share
(%)
Value
(million €)
Share
(%)
EU-28 472.000 159.000 3.340.000
Belgium 13.077,3 3 3.846,8 2 56.113 2
Bulgaria 1.319,7 0 396,1 0 51.870 2
Czech Republic 12.067,4 3 3.434,2 2 135.735 4
Denmark 6.127,7 1 2.294,9 1 38.354 1
Germany 128.084,7 27 47.044,1 30 825.673 25
Estonia 1.091,1 0 252,2 0 11.539 0
Ireland 1.300,2 0 523,6 0 9.858 0
Greece 3.398,8 1 1.294,0 1 26.617 1
Spain 32.722,0 7 10.801,0 7 242.735 7
France 57.894,9 12 18.259,9 11 323.381 10
Croatia 1.363,6 0 468,5 0 28.823 1
Italy 80.308,7 17 24.798,3 16 453.904 14
Cyprus 327,5 0 107,8 0 3.726 0
Latvia 474,9 0 125,9 0 8.534 0
Lithuania 549,6 0 157,1 0 11.989 0
Luxembourg 721,1 0 222,1 0 3.892 0
Hungary 4.235,6 1 1.159,4 1 64.039 2
Malta 95,6 0 34,8 0 1.428 0
Netherlands 20.177,3 4 6.101,0 4 83.924 3
Austria 13.458,0 3 4.856,0 3 69.333 2
Poland 19.370,9 4 5.644,5 4 251.805 8
Portugal 5.662,7 1 1.798,3 1 77.328 2
Romania 3.531,7 1 853,7 1 86.264 3
Slovenia 3.157,5 1 847,1 1 28.432 1
Slovakia 4.005,9 1 1.233,4 1 40.649 1
Finland 6.824,8 1 2.322,3 1 41.289 1
Sweden 14.131,5 3 4.943,7 3 72.513 2
United
Kingdom
36.468,4 8 14.945,1 9 293.342 9
1.3. Main environmental aspects and pressures of the Fabricated
Metal Product manufacturing sector
1.3.1. Environmental aspects
The Fabricated Metal Product manufacturing sector can be characterized by its main
environmental aspects and pressures. According to the EMAS regulation (1221/2009)
an environmental aspect is an element of an organisation’s activities,
products or services that has or can have an impact on the environment. The
environmental aspects of a company are then linked to an environmental pressure,
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 30
e.g. emissions to air or water, production of waste, use of raw materials, etc. In this
context a distinction can be made between direct and indirect environmental aspects:
‘direct environmental aspect’ means an environmental aspect associated with
activities, products and services of the organisation itself over which it has
direct management control;
‘Indirect environmental aspect’ means an environmental aspect which can
result from the interaction of a company with third parties and which can to a
reasonable degree be influenced by a company.
In this paragraph the main environmental aspects and pressures of the entire
Fabricated Metal Product manufacturing sector in the EU-28 are described. The type of
processes applied does not significantly differ depending on the subsectors. Similar
processes and activities are used in the entire Fabricated Metal Products sector, like
logistics, utilities, and manufacturing processes (e.g. removing, forming, additive
processes). There are no clear indications of important differences between the
Fabricated Metal Products subsectors in terms of processes and activities. Therefore,
the analysis of environmental aspects and pressures is performed for the processes
and activities applied in the sector as a whole.
An overview of the direct and indirect environmental aspects and pressures in the
Fabricated Metal Products sector is presented in Figure 7. The direct environmental
aspects of the sector are mainly related to:
Product and manufacturing design
Manufacturing processes:
o Forming processes
o Removing processes
o Additive processes
o Joining processes
o Finishing processes
Supporting processes:
o Management, procurement, supply chain management, quality control
o Logistics handling and storage
o Emissions treatment
o Utilities and maintenance
The indirect environmental aspects, which can be reduced by the sector upstream
and downstream in the value chain, are mainly related to:
Upstream activities:
o Raw material production
o Equipment production
Downstream activities:
o Assembly
o Product finishing
o Protection and packaging
o Logistics
o Use phase, disassembly, recycling
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By working on a higher organizational level both the direct and indirect
environmental aspects can been reduced). This can be done by focusing on
concurrent engineering (see Box 1) and product design. As they encroach deeply on
the value chain, this can only succeed when the partners in the value chain work
together. The initiative can be taken by one or more partners in the value chain.
Box 1. Organizational and temporal scale of environmental impact reduction
approaches – Concurrent Engineering (CE).
Coulter et al. (1995) and Bras (1997) described different environmental impact
reduction approaches and classified each approach based on their organizational and
temporal concern (see Figure 6).
Sustainable development
Manufacturing
processes
Supporting processes
Design processes and concurrent
engineering
ECDM
Industrial Ecology
Product Life Cycle
Human Lifetime
Civilization Span
Scale of temporal concern
Sc
ale
of
org
an
iza
tio
na
l c
on
ce
rn
On
e
ma
nu
factu
rer
X M
an
ufa
ctu
rers
So
cie
ty
Figure 6. Organizational and temporal scale of environmental impact reduction
approaches. Based on Coulter et al. (1995) and Bras (1997). Red line: scope of this
study
One of the first definitions for Concurrent Engineering (CE) is given by Winner, et al.
(1988), as “a systematic approach to the integrated, concurrent design of products
and their related processes, including manufacturing and support. This approach is
intended to cause the developers, from the outset, to consider all elements of the
product life cycle from conception through disposal, including quality, cost, schedule,
and user requirements”. They describe the role of CE for the development of weapons
(which is one of the Fabricated Metal Products sectors). Later the concept is taken
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 32
over by the European Space Agency (ESA, 2012) as "Concurrent Engineering (CE) is
a systematic approach to integrated product development that emphasises the
response to customer expectations. It embodies team values of co-operation, trust
and sharing in such a manner that decision-making is by consensus, involving all
perspectives in parallel, from the beginning of the product life-cycle."
The concept was picked up by Coulter et al. (1995) and Bras (1997), to define
Environmentally Conscious Design and Manufacturing (ECDM). The general goal of
environmentally conscious approaches to product design is the reduction of the
negative environmental impact of a product throughout its life cycle. As shown in
Figure 6, ECDM, similar to design for the environment and life cycle design, needs a
higher level on organization concern. It needs also a mind shift which takes more
time.
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December 2015 33
Indirect aspectsDirect aspectsIndirect aspects
Product & Manufacturing Design
Supporting processes: Manufacturing Processes
Forming processes
Removing processes
Additive processes
Finishing processes
Logistics handling & storage
Utilities and maintenance
Emission treatment
Process design(Product Level)
Infrastructure design(Plant Level)
Manufacturing Processes
Assembly
Protections &
packaging
Otherprocesses
Market Processes
Use Phase
End of Life
Wasteprocessing
Aux
iliar
y em
issi
ons
Air
Em
issi
ons
Wat
er E
mis
sion
s
Solid waste
Solid waste
Joining processes
Manufacturing Processes
Upstream activities
Raw Materials
Energy
Water
Concurrent engineering
Aux
iliar
y em
issi
ons
Air
Em
issi
ons
Wat
er E
mis
sion
s
Product design
Management, procurement, supply chain management,
quality control
Figure 7. Schematic overview of the direct and indirect aspects and environmental pressures of the Fabricated Metal Products sector
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 34
Figure 7 furthermore gives an indication of the main environmental pressures related
to the direct and indirect environmental aspects, indicated with the green arrows.
However, a more detailed overview and assessment of the environmental pressures is
given in section 1.3.2 (Table 4 and Table 5).
1.3.2. Environmental pressures and impacts
The assessment in Table 4 represents to what extent the up- and downstream
activities (indirect aspects) are influenced by the activities, products and services of a
company in the Fabricated Metal Products sector, ranging from a small to a medium
and to a large influence. The categories of the environmental pressures for which this
assessment is conducted, consist of:
Resource use:
o Raw materials
o Energy
o Water
o Consumables
Emissions:
o Water
o Air
o Odour
o Other nuisances (noise, vibration…)
Waste:
o Non-hazardous waste
o Hazardous waste
o Liquid waste
The interaction between the sector and the upstream activities has mainly an influence
on the resource use, especially the use of raw materials, energy and consumables and
on the production of (non-hazardous) waste. As for the downstream activities, the
interaction has mainly an influence on the use of energy and the production of non-
hazardous waste.
The assessment of the environmental pressures of the activities itself, i.e. without
considering the interaction between up- and downstream activities, is presented in
Table 5, for the direct aspects (Fabricated Metal Products sector) and the interface
processes of the indirect aspects. The same categories of environmental pressures are
used as in Table 4. The environmental pressures and aspects assessed in Table 5 as
medium (++) and large (+++) impact can be considered as main environmental
aspects.
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Table 4. Influence on indirect environmental pressures by companies in the Fabricated Metal Products sector (NACE 25)
Legend Product Life Cycle
+ small impact Concurrent Engineering and Product Design
++ medium impact Indirect aspects Direct aspects Indirect aspects Direct & Indirect aspects
+++ large impact upstream NACE 25 Product & Manufacturing Design down stream value chain
/ not applicable
Design Process Supporting processes Manufacturing
Processes Manufacturing
Processes Design Process Market
processes
- raw material production - production equipment
- Management, procurement, supply chain management, quality control - Logistics handling and storage - Emission treatment - Utilities and maintenance
- Forming processes - Removing processes - Additive processes - Joining processes - Finishing processes - Packaging processes
- Assembly - Product finishing - Protection & Packaging - Logistics
- Material selection
- Use Phase - Refurbishment - Disassembly - Material recycling
Re
sou
rce
use
Raw Materials +++ See Table 5 + +++ /
Energy ++
+++ ++ /
Water +
/ + /
Consumables +
+ ++ /
Emis
sio
ns
Water + See Table 5 / / /
Air +
+ / /
Odour /
/ / /
Other (noise, vibration, etc.) + + / +
Was
te Non hazardous ++ See Table 5 ++ + ++
Hazardous + / / +
Liquid waste + + / /
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Table 5. Assessment of the environmental pressures of the direct aspects (NACE 25) and interface processes of the indirect aspects
Legend
Direct aspects
+ small impact
Infrastructure design Process Design
++ medium impact
Supporting processes Manufacturing Processes
+++ large impact
- M
anag
em
ent,
pro
cure
men
t, s
up
ply
chai
n m
anag
emen
t, q
ual
ity
con
tro
l
Logi
stic
s, h
and
ling
and
sto
rage
Emis
sio
n T
reat
men
t:
- w
ater
tre
atm
ent
- ai
r tr
eatm
ent
Uti
litie
s an
d m
ain
ten
ance
:
- p
roce
ss h
eati
ng
& c
oo
ling
- co
mp
ress
ed a
ir
- H
VA
C b
uild
ing
Form
ing
Pro
cess
es:
- fo
rgin
g
- b
end
ing
Rem
ovi
ng
Pro
cess
es:
- tu
rnin
g, m
illin
g,
- ED
M p
roce
sses
- cu
ttin
g, p
un
chin
g, la
ser,
Ad
dit
ive
pro
cess
es:
- 3
D p
rin
tin
g
Join
ing
Pro
cess
es:
- w
eld
ing
- b
razi
ng
Fin
ish
ing
Pro
cess
es:
- h
eat
trea
tmen
t
- su
rfac
e tr
eatm
ent
elec
tro
chem
ical
- la
ser
op
erat
ion
s
Pac
kagi
ng
/ not applicable
Re
sou
rce
use
Raw Materials + + + + / / + + + + + + + + + + +
Energy + + + + + + + + + + + + + + + + + + /
Water + / / + / + / / + + + /
Consumables + + + + + / + + / + + + + /
Emis
sio
ns Water / / + + + + / + / / + + + /
Air / + + / / + / + + ++ /
Odour / / + + / + / + + ++ /
Other (noise,) / + + + + + + + + + + /
Was
te Non hazardous + / + + / + + + + + + + + +
Hazardous / / + / / / / / + + + /
Liquid waste / / / / / + / / + + + /
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Within the design processes and concurrent engineering the most important
environmental pressures are related to the use of raw materials, energy and
consumables. For example companies having an impact on the product design can
significantly reduce the environmental impact per manufactured product by material
and process selection, product design optimization for manufacturing processes etc.
Some subsectors can currently have less freedom in process selection compared to
other subsectors, e.g. manufacturing of wire products, forging, pressing, stamping and
roll-forming of metal, powder metallurgy. Those sectors are defined based on the
processes. Specific products can often be strongly linked to the production process,
e.g. hot milling of I-beams (in subsector ‘manufacturing of metal structures and part
of structures’).
Management, procurement, supply chain management and quality control are
considered as supporting processes to the manufacturing activities in this study.
Although these supporting processes themselves have in general no are very low
impact on the environment, they can have a high potential in influencing the
environmental impact of the Fabricated Metal Products activities, especially regarding
resource use or waste generation. For example, the implementation of an efficient
supply chain management system in a company in the sector will not require any
resource use or produce any waste, however, this system can lead to a reduction in
resource use in the Fabricated Metal Product manufacturing activities by efficiently
managing (e.g. on time, demand) the resource supply. Similarly, the implementation
of an efficient quality control system does not produce any emissions, but it can lead
to a reduction in emissions or waste generation in the Fabricated Metal Product
manufacturing activities by improving process steps.
Logistics, handling and storage are not considered in this analysis as a main
environmental aspect. The impact of these activities or services strongly depends on
the product volume and on the product sensitivity to damage, e.g. by corrosion or
surface damage. Important factors affecting the impact of handling and storage of
products are temperature, shelf life, hazardous material storage requirements
(consumables), inside or outside storage possibilities, etc. Logistics is either organized
and managed by the company itself, by the suppliers or outsourced to a private
logistic organization.
Emission treatment, mainly treatment of water and air emissions and of hazardous
products, can require a considerable amount of energy. The treatment of emissions is
mainly applied and related to the impacts of the (surface) finishing processes in the
sector, leading to important emissions of discharged water and non-hazardous waste.
The utilities applied in the sector (e.g. heating, cooling, compressed air, HVAC) can
require significant energy consumption. Therefore, heat recovery and smart controls
can have a high potential in the reduction of energy consumption. In general, closed
(cooling or heating) systems have a lower impact compared to open systems.
Furthermore, these processes can lead to considerable noise and/or vibrations. In
general, the utility department is also responsible for the maintenance of the
production plant.
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As part of the manufacturing processes of the Fabricated Metal Products sector, the
forming processes mainly consist of forging (forging, pressing, stamping and roll-
forming of metal) and bending. The use of raw materials (ferrous and non-ferrous
metals) and energy and the emission of noise and/or vibrations are the main
environmental pressures related to these aspects. The energy used is mainly electric
energy, for thermal processes gas is applied.
Several removing processes are widely applied throughout all Fabricated Metal
Products subsectors, e.g. drilling, turning, milling. Other processes are more related to
one or more specific subsectors. EDM (Electrical Discharge Machining) processes are
for example used in subsectors making products with high added value and precision
(ammunition, other products …). Cutting, punching and laser cutting are applied in the
fabrication of sheet metal and tubing. Most removing processes however are
characterized by a high impact on raw material and (electric) energy use. Almost all
removed material consists of non-value added material. Therefore, near net shape
processes have a high potential. Consumables, such as cooling and lubricating
consumables, are widely used in the entire Fabricated Metal Products sector. The
nature of the processes generate non-hazardous waste (e.g. chips, turning, cut outs)
containing a small amount of consumables (mainly coolant and/or lubrication).
Additive processes (3D printing) are processes used in specific Fabricated Metal
Products subsectors, making products with high added value and precision
(ammunition, other products, etc.). These processes are typically characterized by a
considerable impact on the use of raw materials and energy required by the
processes.
Thermal joining processes, mainly welding and brazing, are generally applied in
most subsectors except for manufacturing of wire products, forging, pressing,
stamping and roll-forming of metal; powder metallurgy, fasteners and screws. Other
joining processes, such as gluing and pressing are more specific and primarily applied
for high end products. Apart from the use of energy and consumables (e.g. welding
electrodes, shielding gases, glues), these processes can lead to air emissions (e.g.
abrasive dust) and emissions of odour.
The finishing processes applied in the sector can differ between the various
subsectors, depending on the products and applications. Heat treatment processes for
example largely differ for ferrous and non-ferrous metals (e.g. hardening and
extrusion). Laser processes like engraving and polishing are used for specific high
value products. Finishing processes such as electrochemical surface treatment, have a
high impact on water consumption since water based solutions are used in these
processes. The waste water from those processes furthermore contains significant
amounts of contaminants, due to the several process steps requiring a large set of
chemicals and additives. Next to the contaminated waste water, hazardous waste and
liquid waste streams are generated (e.g. (heavy) metals, organic compounds).
Packaging processes in the Fabricated Metal Products sector have to ensure the
quality of the products, e.g. protecting against corrosion at storage and transport.
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Packaging processes will mainly have an impact on the use of raw materials
(packaging materials) and the production of non-hazardous waste streams.
Similar to the upstream activities, the sector (NACE 25 organisations) can have a
significant impact on material effectiveness in the downstream activities through
material selection and process selection by concurrent engineering (product &
process).
The concept and benefits for improving the environmental performance of Fabricated
Metal Products companies will be described under CHAPTER 2 Best environmental
management practice.
By using an environmentally extended multi-regional input-output database including
highly-detailed national input-output tables (i.e. the EORA database7), the direct and
indirect environmental impacts of the Fabricated Metal Products sector can be
analysed. This database is used to derive direct, indirect and total coefficients.
Although EORA uses a slightly different sector classification system than NACE Rev. 2
(see Table 6), which implies imperfect sectoral data matches, it still offers valuable
information on coefficients for the comparison of the subsectors. An input-output
analysis allows to consistently mapping both the direct and indirect effects of supplies
to the sector. Direct effects are triggered by the supplies to the sector; indirect effects
take into account the complete value chain perspective of these deliveries (upstream
activities); total effects consider both the direct and indirect effects. An input-output
analysis allows expressing the socio-economic impact and related environmental
impact in direct, indirect and total coefficients. This provides key numbers which
immediately can be used analytically.
Table 6. Comparison of sector classification systems of EORA (UK) and NACE Rev.2
EORA classification (UK) NACE
Rev.2
Manufacture of metal structures and parts of structures 25.11
Manufacture of builders' carpentry and joinery of metal 25.12
Manufacture of central heating radiators and boilers 25.21
Manufacture of tanks, reservoirs and containers of metal 25.29
Manufacture of steam generators, except central heating hot water boilers 25.30
Manufacture of weapons and ammunition 25.40
Forging, pressing, stamping and roll forming of metal; powder metallurgy 25.50
Treatment and coating of metals 25.61
General mechanical engineering 25.62
Manufacture of cutlery 25.71
Manufacture of locks and hinges 25.72
Manufacture of tools 25.73
Manufacture of steel drums and similar containers 25.91
Manufacture of light metal packaging 25.92
Manufacture of wire products 25.93
7 Link: www.worldmrio.com
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EORA classification (UK) NACE
Rev.2
Manufacture of fasteners, screw machine products, chains and springs 25.94
Manufacture of other fabricated metal products not elsewhere classified 25.99
Some environmental parameters can be derived from the Eurostat database for the
entire sector (NACE 25), e.g. direct emissions of NMVOC and CO2. In order to
calculate the (direct and indirect) impacts of the individual subsectors, the coefficients
from the EORA (UK) database can be used. These calculations however mainly give an
indication of the relative importance of the individual subsectors related to a specific
environmental parameter, given the constraints of using highly-detailed national
input-output tables.
Table 7 and Figure 8 present an overview of the analysis based on the Eurostat and
EORA (UK) database.
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Table 7. Direct and total emissions and resource use of the Fabricated Metal Products (sub) sectors (Eurostat and EORA, 2011)
Parameter Source 10-33
(manufacturing) -
tonnes
C 25 -
tonnes
Share of NACE 25 (%)
25.1 25.2 25.3 25.4 25.5 25.6 25.7 25.9
Direct emissions – NMVOC Eurostat 2.381.421 207.173
Direct emissions – CO2 Eurostat 884.086.665 15.040.502
Direct emissions - total GHG
(CO2-eq.)
EORA
27 4 2 3 12 20 10 22
Total emissions - total GHG (CO2-
eq.)
EORA
29 4 2 2 11 20 9 23
Direct emissions - air quality
NMVOC
EORA
12 10 4 2 9 13 15 34
Total emissions -air quality
NMVOC
EORA
23 8 3 3 10 17 12 25
Direct use - total water EORA 28 4 2 3 12 20 11 21
Total use - total water EORA 29 5 2 3 10 18 9 23
Direct use - energy EORA 26 4 2 3 12 20 10 23
Total use - energy EORA 29 4 2 2 11 21 8 23
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Based on the analysis in Table 7, the indirect emissions of the sector can be
calculated. Figure 8 presents the relative importance of both the direct and indirect
emissions of NMVOC (non-methane volatile organic compounds), GHG (greenhouse
gas) emissions, energy use and water use. Since the data in EORA (UK) for material
use are not complete, this parameter is not calculated.
Figure 8. Relative share of direct and indirect emissions of the Fabricated Metal
Products sector (EORA, 2011)
Figure 8 clearly indicates that the relative share of direct and indirect emissions can
significantly differ depending on the environmental parameter. Ca. 45% of the NMVOC
emissions in the value chain originate from the sector (NACE 25), while for water use,
energy use and GHG emissions this share of direct emissions is ca. 1, 4 and 8%,
respectively. The largest part of these indirect emissions originates from upstream
activities like raw materials production requiring significant amounts of energy and
water and producing GHG emissions.
The Sankey diagrams in Figure 9 and Figure 10 give an overview of the material flows
of steel and aluminium respective. The sector (NACE 25) uses metals from founding
industry to produce semi-finished products and end-products. However they are not
the only sector doing this kind of activities. Below we give an illustrative overview:
- NACE 28: Manufacture of machinery and equipment n.e.c; e.g.: NACE 28.1.:
Manufacture of engines and turbines, except aircraft, vehicle and cycle
engines; NACE 28.1.1: Manufacture of engines and turbines, except aircraft,
vehicle and cycle engines;
- NACE 29.2: Manufacture of bodies (coachwork) for motor vehicles;
manufacture of trailers and semi-trailers (NACE 29.2);
- NACE 29.3: Manufacture of parts and accessories for motor vehicles;
- NACE 30.1: Building of ships and boats,
- NACE 31 Manufacture of furniture;
- NACE 32: Other manufacturing.
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Figure 9. Basis: Sankey diagram of steel flow – the activities of the Fabricated Metal Product manufacturing sector are situated in
the green/blue areas (Allwood, 2011); double red line: scope of this study
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December 2015 44
Figure 10. Basis: Sankey diagram of aluminium flow – the activities of the Fabricated Metal Product manufacturing sector are
situated in the green/blue areas (Allwood, 2011); double red line: scope of this study
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 45
1.4. EMAS and the Fabricated Metal Product manufacturing sector
In the EU-28 there are a total of 95 companies in the Fabricated Metal Product
manufacturing sector (NACE division 25) having an EMAS registration. Since some of
these companies have an EMAS registration number for more than one NACE division
25 group, the total number of EMAS registrations in the EU-28 in the Fabricated Metal
Product manufacturing subsectors equals 171 (Error! Reference source not found.).
The treatment and coating of metals (NACE 25.61) is the class with the highest number
of EMAS registrations, followed by the manufacture of metal structures and parts of
structures (NACE 25.11), machining (NACE 25.62) and manufacture of other fabricated
metal products n.e.c. (NACE 25.99). In Italy 40 EMAS registered organisations are
located which is a significantly higher number compared to other EU-28 member states.
Table 8. Overview of EMAS registrations (registration numbers and organisations) in
EU-28 in the Fabricated Metal Products sector
(http://ec.europa.eu/environment/emas/register/)8
NACE code AT BG CZ DE DK ES GR HU IT PL PT RO SE UK Total
25.11 1 1 4 4 2 2 7 2 1 1 25
25.12 2 3 2 2 1 10
25.21 3 1 4
25.29 3 1 1 5
25.30 3 1 4
25.40 3 3
25.50 1 4 1 1 2 9
25.61 1 1 8 1 4 21 1 37
25.62 6 2 1 6 15
25.71 3 1 4
25.72 1 3 4
25.73 1 1 4 6
25.91 4 1 5
25.92 5 1 2 1 9
25.93 1 4 1 2 1 9
25.94 1 5 1 7
25.99 1 6 1 1 5 1 15
Total 6 1 10 71 1 15 3 3 48 1 5 1 5 1 171
Number of
companies
5 1 6 17 1 12 2 3 40 1 4 1 1 1 95
8 As some data in the EU EMAS register are out of date or have expired, a substantial update of the system is
presently underway. Current figures may not reflect the true number of organisations and sites in EU Member
States. This may take a few weeks to be completed (see disclaimer at
http://ec.europa.eu/environment/emas/register/, last accessed on 10/03/15).
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 46
1.5. EU legislation, policy instruments and best practice guidance
Processes and environmental aspects of the NACE 25 (sub)sectors that are covered by
one of the BREFs, directly or indirectly linked to the manufacture of fabricated metal
products as well as by EU legislation, policy instruments and best practice guidance are
excluded from the scope of this study (see Figure 7).
IED and BREFs
The Industrial Emissions Directive (IED) (Directive 2010/75/EU) is an integration (and
revision) of the IPPC Directive (2008/1/EC) with the Large Plant Combustion Directive
(2001/80/EC), the Waste Incineration Directive (2000/76/EC), the Solvent Directive
(1999/13/EC) and three Directives for the titanium dioxide industry (78/176/EEC -
82/883/EEC - 92/112/EEC). The IED obligates the EU member states to prevent,
reduce and as far as possible eliminate pollution arising from industrial activities. The
IED entered into force 6 January 2011 and concerns all installations where one or more
of the activities included in annex I of the directive. In order to ensure the prevention
and control of pollution, each installation should operate only if it holds a permit or, in
the case of certain installations and activities using organic solvents, only if it holds a
permit or is registered. The permit should include all the measures necessary to
achieve a high level of protection of the environment as a whole and to ensure that the
installation is operated in accordance with the general principles governing the basic
obligations of the operator. The permit should also include emission limit values for
polluting substances, or equivalent parameters or technical measures, appropriate
requirements to protect the soil and groundwater and monitoring requirements. Permit
conditions should be set on the basis of best available techniques.
In order to determine best available techniques and to limit imbalances in the Union as
regards the level of emissions from industrial activities, reference documents for best
available techniques (BAT reference documents) are drawn up. BREFs are sectoral
reference reports and give an overview of what BAT are and which environmental
performances can be achieved with BAT. Table 9 gives an overview of the BREFs
directly or indirectly linked to the manufacture of fabricated metal products. Besides the
reference to annex I of the IED, a short description is given of the processes / activities
as well as the techniques and environmental aspects within scope of BREF. Further, the
table contains the link to Fabricated Metal Products by referring to the processes as
outlined in paragraph 1.3.
The BREFs STM and STS are the most direct linked to the Fabricated Metal Products
value chain. As the case for the installations under de scope of these BREFs, besides
large installations, most of the Fabricated Metal Product manufacturing installations are
small or medium sized (Eurostat 2011 and 2012).
The surface treatment of metals and plastics is carried out in Europe in more than
18300 installations, both IPPC and non-IPPC. The sector is composed of small private
companies as well as facilities owned by multinational corporations. The large majority
are small or medium enterprises9 (BREF STM). More than 55% are specialist surface
9 EU recommendation 2003/361:
Medium-sized: <250 employees and ≤ € 50 m (turnover) or ≤ € 43 m (balance sheet total)
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 47
treatment installations. The remaining 45% are surface treatment shops within another
installation typically also an SME. Surface treatment using solvents is carried out in
more than 500000 companies (EU-25, IPPC as well as non-IPPC). Most of these
companies are also SMEs (BREF STS).
Small: <50 employees and ≤ € 10 m (turnover) or ≤ € 10 m (balance sheet total)
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 48
Table 9. Global overview of processes/activities/techniques within the scope of BREFs (directly or indirectly) linked to the manufacture
of Fabricated Metal Products
BREF Scope BREF (IED,
annex 1)
Global overview of
processes / activities
within scope of BREFs
Techniques and environmental
aspects within scope of BREFs
Link to Fabricated Metal
Products value chain (see
Figure 7)
Surface
Treatment of
Metals and
Plastics (BREF
STM, August
2006)
2.6.
Installations for
surface treatment of
metals and plastic
materials using an
electrolytic or
chemical process
where the volume of
the treatment vats
exceeds 30 m³
- water-based
electrolytic or chemical
processes
- surface treatment of
metals, barrel
processing, continuous
coil-large scale steel,
sheet processing for
aluminium lithography
plates, printed circuit
board manufacturing
- apply environmental
management tools (general
aspects)
- optimize design, construction and
operation of installation to prevent
and control unplanned releases,
and to prevent soil and
groundwater contamination
- apply general operational issues
to reduce the amount of processing
required and the consequent
consumptions and emissions
- optimize utility inputs and their
management to optimize electricity
consumption and the amount of
energy and/or water used in
cooling, and to reduce fuels (used
for heating) and heat losses
- reduce and control drag-out
- optimize raw material usage
- optimize electrode techniques
- use less hazardous substances by
substitution
- optimize maintenance: removal
Covered:
Direct aspects of
- finishing processes, in
particular water-based
electrolytic or chemical
processes
(all aspects)
Direct aspects (in general) of
supporting processes:
- logistics, handling, storage
- emission treatment (water
and air)
- utilities
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 49
BREF Scope BREF (IED,
annex 1)
Global overview of
processes / activities
within scope of BREFs
Techniques and environmental
aspects within scope of BREFs
Link to Fabricated Metal
Products value chain (see
Figure 7)
of contaminants
- optimize process metals recovery
(in conjunction with drag-out
controls)
- apply post-treatment activities,
including drying and de-
embrittlement
- optimize treatment of air
emissions
- optimize treatment of waste
water emissions
- optimize waste management
(drag-out control and
maintenance)
- apply noise management: good
practice and/or engineered
techniques
Surface
Treatment
using Organic
Solvents (BREF
STS, August
2007)
6.7.
Installations for the
surface treatment of
substances, objects
or products using
organic solvents, in
particular for
dressing, printing,
coating, degreasing,
waterproofing,
sizing, painting,
- organic solvent based
surface treatment
processes (activities
also regulated by the
Solvent Emissions
Directive, 1999/13/EC)
- printing processes
using solvents on a
large scale: headset
web offset, flexible
packaging and
- optimize installation design,
construction and operation to
minimize consumptions and
emissions (particularly to soil,
water and groundwater, as well as
to air)
- monitor solvent emissions in
order to minimize air emissions
- reduce water consumption and/or
conserve raw materials in water-
based treatment processes
Covered:
Direct aspects of
- finishing processes, in
particular organic solvent
based surface treatment
processes
(all aspects)
Direct aspects (in general) of
supporting processes:
- logistics, handling, storage
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December 2015 50
BREF Scope BREF (IED,
annex 1)
Global overview of
processes / activities
within scope of BREFs
Techniques and environmental
aspects within scope of BREFs
Link to Fabricated Metal
Products value chain (see
Figure 7)
cleaning or
impregnating, with a
consumption
capacity of more
than 150 kg per hour
or more than 200
tonnes per year
publication gravure
- coating and/or
painting of winding
wires, wars and
commercial vehicles,
buses, trains,
agricultural equipment,
ships and yachts,
aircraft, steel and
aluminium coil, metal
packaging, furniture and
wood, and other metal
and plastic surfaces
- adhesive application in
the manufacture of
abrasives and adhesive
tapes
- wood impregnation
with preservatives
- with these activities
associated cleaning and
degreasing activities
- minimize energy usage
- optimize raw material
management
- optimize systems for surface
treatment, application and
drying/curing
- optimize cleaning
- use less hazardous substances
(substitution of solvent-based
coatings by water-soluble
alternatives)
- optimize treatment of emissions
to air and waste gas
- minimize particulates discharged
to air from paint spraying
- optimize treatment of waste
water
- optimize materials recovery and
waste management
- prevent odour and noise nuisance
- emission treatment:
emissions to water and air
- utilities
Ferrous Metals
Processing
Industry (BREF
FMP, December
2001)
2.2.
Installations for the
production of pig iron
or steel (primary or
secondary fusion)
- production of ferrous
metals
- hot and cold forming
(rolling and drawing of
steel)
- optimize thermal efficiency and
reduce NOx emissions of furnaces
- optimize cleaning and reuse,
treatment and abatement of oil
emulsions
Covered:
Direct aspects of
- upstream activities: raw
material production
(all aspects)
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 51
BREF Scope BREF (IED,
annex 1)
Global overview of
processes / activities
within scope of BREFs
Techniques and environmental
aspects within scope of BREFs
Link to Fabricated Metal
Products value chain (see
Figure 7)
including continuous
casting, with a
capacity exceeding
2,5 tonnes per hour
2.3.
Installations for the
processing of ferrous
metals:
(a) hot-rolling mills
with a capacity
exceeding 20 tonnes
of crude steel per
hour
(b) smitheries with
hammers the energy
of which exceeds 50
kilojoule per
hammer, where the
calorific power used
exceeds 20 MW
(c) application of
protective fused
metal coats with an
input exceeding 2
tonnes of crude steel
per hour
2.4.
Ferrous metal
- continuous hot dip
coating
- batch galvanizing
- optimize alkaline degreasing,
pickling, heating, fluxing, rinsing
- optimize treatment of process
water and waste water emissions
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 52
BREF Scope BREF (IED,
annex 1)
Global overview of
processes / activities
within scope of BREFs
Techniques and environmental
aspects within scope of BREFs
Link to Fabricated Metal
Products value chain (see
Figure 7)
foundries with a
production capacity
exceeding 20 tonnes
per day
Non Ferrous
Metals
Industries
(BREF NFM,
December
2001)
2. Production and
processing of metals
2.1.
Metal ore (including
sulphide ore)
roasting or sintering
installations
2.5. Installations:
(a) for the
production of non-
ferrous crude metals
from ore,
concentrates or
secondary raw
materials by
metallurgical,
chemical or
electrolytic processes
(b) for the smelting,
including the
alloyage, of non-
ferrous metals,
including recovered
products, (refining,
- production of primary
and secondary non-
ferrous metals:
- copper (including Sn
and Be) and its alloys
- aluminium
- zinc, lead and
cadmium, (+ Sb, Bi, In,
Ge, Ga, As, Se, Te)
- precious metals
- mercury
- refractory metals
- ferro alloys
- alkali and alkaline
earth metals
- nickel and cobalt.
- carbon and graphite
- reduce emissions to air (e.g. SO2,
dust, metal compounds, organic
compounds, fluorides (incl. HF),
VOCs
(including dioxins), odours) and
waste water (e.g. metal and
organic compounds)
- minimize process residues and
waste
Covered:
Direct aspects of
- upstream activities: raw
material production
(all aspects)
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 53
BREF Scope BREF (IED,
annex 1)
Global overview of
processes / activities
within scope of BREFs
Techniques and environmental
aspects within scope of BREFs
Link to Fabricated Metal
Products value chain (see
Figure 7)
foundry casting, etc.)
with a melting
capacity exceeding 4
tonnes per day for
lead and cadmium or
20 tonnes per day
for all other metals
6.8.
Installations for the
production of carbon
(hard-burnt coal) or
electrographite by
means of incineration
or graphitization
Smitheries and
Foundries
Industry (BREF
SF)
-processing of ferrous
metals as smitheries
-ferrous metal foundries
-smelting, including the
alloyage, of non-ferrous
metals, including
recovered products
(refining, foundry
casting, etc.).
The following foundry
process steps are
covered:
• pattern making
-prevention of soil and water
pollution and optimization of the
internal recycling of scrap metal
-optimization of the furnace
efficiency and minimisation of
residue production
-minimizing consumptions
-reduction of VOCs and odour
emissions
-reduction of (fugitive) emissions
-energy efficiency
-regeneration or re-use of sand
(auxiliary)
-dust and solid residues: treatment
Indirect aspects
upstream
Design Process
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 54
BREF Scope BREF (IED,
annex 1)
Global overview of
processes / activities
within scope of BREFs
Techniques and environmental
aspects within scope of BREFs
Link to Fabricated Metal
Products value chain (see
Figure 7)
• storage and handling
of raw materials
• melting and metal
treatment
• mould and core
production, and
moulding techniques
• casting or pouring and
cooling
• shake-out
• finishing
• heat treatment
and re-use
-noise reduction
-prevent pollution at the
decommissioning stage.
-environmental management tools
Energy
Efficiency
(BREF ENE,
February 2009)
all IPPC installations - guidelines for energy
efficiency
- optimize energy efficiency
- minimize energy use
- minimize air emissions
Covered:
Direct aspects (in general) of
- utilities: energy use; air
emissions
Industrial
Cooling
Systems (BREF
ICS,
December
2001)
all IPPC installations - cooling systems that
are considered to work
as auxiliary
systems for the normal
operation of an
industrial process
- optimize cooling
- minimize the use of water,
energy, consumables
- minimize emissions to water and
air
Covered:
Direct aspects (in general) of
- utilities: use of water,
energy, consumables;
emissions to water and air
Large
Combustion
Plants (BREF
LCP, May 2005)
all combustion
installations with a
rated thermal input
exceeding 50 MW
- power generation
industry
- combustion plants
working on conventional
fuels (e.g. coal, lignite,
- optimize combustion
- minimize energy use
- minimize air emissions
Covered:
Direct aspects (in general) of
- utilities: use of energy;
emissions to air
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 55
BREF Scope BREF (IED,
annex 1)
Global overview of
processes / activities
within scope of BREFs
Techniques and environmental
aspects within scope of BREFs
Link to Fabricated Metal
Products value chain (see
Figure 7)
biomass, peat, liquid
and gaseous fuels,
including hydrogen and
biogas) not covered
within another sector
BREF.
- co-combustion of
waste and recovered
fuel in large combustion
plants
- upstream and
downstream activities
directly associated to
the combustion process
Waste
Treatment
Industries
(BREF WT,
August 2006)
5.1
Disposal or recovery
of hazardous waste
with a capacity
exceeding 10 tonnes
per day …
5.3
(a) Disposal of non-
hazardous waste
with a capacity
exceeding 50 tonnes
per day
(b) Recovery, or a
mix of recovery and
- management of
hazardous and non-
hazardous waste
- optimize temporary storage of
waste, blending and mixing,
repackaging, waste reception,
sampling, checking and analysis,
waste transfer and handling
installations, and waste transfer
stations
- optimize mechanical, physico-
chemical and biological treatments
of liquid waste
- optimize waste recovery (e.g.
reconcentration of acids and bases,
recovery of metals from liquid and
solid photographic waste,
Covered:
Direct aspects of
- downstream activities:
treatment of hazardous and
non-hazardous waste
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 56
BREF Scope BREF (IED,
annex 1)
Global overview of
processes / activities
within scope of BREFs
Techniques and environmental
aspects within scope of BREFs
Link to Fabricated Metal
Products value chain (see
Figure 7)
disposal, of non-
hazardous waste
with a capacity
exceeding 75 tonnes
per day …
5.5
Temporary storage
of hazardous waste
not covered under
point 5.4 pending
any of the activities
listed in points 5.1,
5.2, 5.4 and 5.6 with
a total capacity
exceeding 50 tonnes,
excluding temporary
storage, pending
collection, on the site
where the waste is
generated
regeneration of organic solvents
and spent ion exchange resins, and
re-refining of waste oils)
- optimize the production of solid
and liquid fuels from hazardous
and non-hazardous waste
Waste
Incineration
(BREF WI,
August 2006)
5.2
Disposal or recovery
of waste in waste
incineration plants or
in waste co-
incineration plants:
(a) for non-
hazardous waste
with a capacity
- incineration, pyrolysis
and gasification of
hazardous and
municipal waste
- optimize reception, handling and
storage of waste
- optimize waste pre-treatment
- optimize flue-gas treatment
- optimize waste water treatment
- optimize energy recovery
Direct aspects of
- downstream activities:
treatment of hazardous and
non-hazardous waste
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 57
BREF Scope BREF (IED,
annex 1)
Global overview of
processes / activities
within scope of BREFs
Techniques and environmental
aspects within scope of BREFs
Link to Fabricated Metal
Products value chain (see
Figure 7)
exceeding 3 tonnes
per hour;
(b) for hazardous
waste with a capacity
exceeding 10 tonnes
per day.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 58
As indicated in Table 9 some direct environmental aspects from Fabricated Metal
Product manufacturing installations are already covered by BREFs under the IED. Some
examples of direct environmental parameters from manufacturing installations already
covered by BREFs are given in Table 10.
Table 10. Examples of direct environmental parameters covered in the BREFs (directly
or indirectly) linked to the manufacture of Fabricated Metal Products
BREF environmental issues
covered in the BREFs
Parameters
Industrial processes & related
operations leading to BAT-
AELs10
emission into water
metals, surfactants (NPE and
PFOS), complexing agents
(cyanides and EDTA), chlorides,
sulphates, phosphates, nitrates
and anions
air emissions
NOx, HCl, HF, acid particulates,
hexavalent chromium mist,
ammonia, dust and solvents
Industrial processes & related
operations NOT leading to
BAT-AELs11
energy energy consumption
consumables use of chemicals for cleaning
water water consumption
raw materials usage of raw materials
waste occurrence of solid and liquid
wastes
EU legislation, policy instruments and best practice guidance
As already described above, some processes and direct environmental aspects from
Fabricated Metal Product manufacturing installations are already covered by BREFs
under the IED. Table 11 gives an overview of the EU legislation, policy instruments and
best practice guidance relevant for products and processes of the NACE 25
(sub)sectors. The tables include also a short description of the field of application.
Further a link is made to the processes and environmental aspects as outlined in
paragraph 1.3.
10 Best Available Technique Associated Emission Level 11 E.g. water performancy levels, material efficiency levels, solvent re-using levels.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 59
Table 11. Overview of the EU legislation, policy instruments and best practice guidance relevant for products and processes of the
NACE 25 (sub)sectors
environmental
issues
reference short description of the field of
application
source link with Fabricated
Metal Products
activities (see
paragraph 1.3)
link with
environmental
parameters
GENERAL Industrial
Emissions
Directive
(IED,
2010/75/E
U)12
IPPC installations - BREFs
The European Union (EU) defines
the obligations to be met by
industrial activities with a major
pollution potential. It establishes
a permit procedure and lays
down requirements, in particular
with regard to discharges. The
objective is to avoid or minimize
polluting emissions in the
atmosphere, water and soil, as
well as waste from industrial and
agricultural installations, with the
aim of achieving a high level of
environmental and health
protection.
http://eippcb.jrc.ec
.europa.eu/index.ht
ml
manufacturing
processes (all)
resource use (all),
emissions (all), waste
(all)
12 DIRECTIVE 2010/75/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 24 November 2010 on industrial emissions (integrated pollution prevention and
control)
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 60
environmental
issues
reference short description of the field of
application
source link with Fabricated
Metal Products
activities (see
paragraph 1.3)
link with
environmental
parameters
ENERGY Directive
2012/27/E
U13
Energy
efficiency
directive
This directive covers various
measures to improve the overall
European energy efficiency and
defines some concrete
obligations for industry:
enterprises that are not SMEs are
subject to an energy audit by 5
December 2015 and at least
every four years AND new or
substantially refurbished thermal
electricity generation installation
with a total thermal input
exceeding 20 MW should carry
out a cost-benefit analysis
application of high-efficiency
cogeneration and/or efficient
district heating and cooling
http://eur-
lex.europa.eu/legal
-
content/EN/TXT/PD
F/?uri=CELEX:3201
2L0027&from=EN
supporting
processes - process
heating and cooling
(not for SMEs and
existing thermal
electricity
generation
installations)
energy efficiency
cogeneration heating
cooling
WATER Directive
2000/60/E
C14
Water
framework
This framework-Directive has
several objectives such as
preventing and reducing
pollution, promoting sustainable
water usage, protecting the
http://ec.europa.eu
/environment/wate
r/water-
framework/index_e
n.html
finishing processes
- surface treatment
water (use /
discharge)
13 Directive 2012/27/EU of the European Parliament and of the Council of 25 October 2012 on energy efficiency, amending Directives 2009/125/EC and 2010/30/EU
and repealing Directives 2004/8/EC and 2006/32/EC 14 Directive 2000/60/EC of the European Parliament and of the Council of 23 October 2000 establishing a framework for Community action in the field of water
policy
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 61
environmental
issues
reference short description of the field of
application
source link with Fabricated
Metal Products
activities (see
paragraph 1.3)
link with
environmental
parameters
directive environment, improving the state
of aquatic eco-systems and
reducing the effects of floods and
droughts.
CONSUMABLES REACH
1907/200615
REACH is a regulation of the EU,
adopted to improve the
protection of human health and
the environment from the risks
that can be posed by chemicals,
while enhancing the
competitiveness of the EU
chemicals industry. It also
promotes alternative methods for
the hazard assessment of
substances in order to reduce the
number of tests on animals.
http://echa.europa.
eu/regulations/reac
h
manufacturing
processes
(removing, joining,
finishing processes)
resource use (all)
emissions to
WATER
2000/60/E
C16
This framework-Directive has
several objectives such as
preventing and reducing
pollution, promoting sustainable
water usage, protecting the
environment, improving the state
http://ec.europa.eu
/environment/wate
r/water-
framework/index_e
n.html
finishing processes
- surface treatment
supporting
processes -
wastewater
treatment
water (use /
discharge)
15 Regulation (EC) No 1907/2006 of the European Parliament and of the Council on the Registration, Evaluation, Authorisation and Restriction of Chemicals 16 Directive 2000/60/EC of the European Parliament and of the Council of 23 October 2000 establishing a framework for Community action in the field of water
policy
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 62
environmental
issues
reference short description of the field of
application
source link with Fabricated
Metal Products
activities (see
paragraph 1.3)
link with
environmental
parameters
of aquatic eco-systems and
reducing the effects of floods and
droughts.
2008/105/
EC 17
This Directive sets out
environmental quality standards
(EQS) concerning the presence in
surface water of certain
substances or groups of
substances identified as priority
pollutants on account of the
substantial risk they pose to or
via the aquatic environment
The EQS in Directive
2008/105/EC are limits on the
concentration of the priority
substances and eight other
pollutants in water (or biota), i.e.
thresholds which must not be
exceeded if good chemical status
is to be met
Directive
2008/105/EC -
EUR-Lex - Europa
finishing processes
- surface treatment
supporting
processes -
wastewater
treatment
water (discharge)
17 Directive 2008/105/EC of the European Parliament and of the Council of 16 December 2008 on environmental quality standards in the field of water policy,
amending and subsequently repealing Council directives 82/176/EEC, 83/513/EEC, 84/156/EEC, 84/491/EEC, 86/280/EEC and amending Directive 2000/60/EC
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 63
environmental
issues
reference short description of the field of
application
source link with Fabricated
Metal Products
activities (see
paragraph 1.3)
link with
environmental
parameters
2006/118/
EC18
This Directive is designed to
prevent and combat groundwater
pollution. Its provisions include:
- criteria for assessing the
chemical status of groundwater
- criteria for identifying
significant and sustained upward
trends in groundwater pollution
levels, and for defining starting
points for reversing these trends
- preventing and limiting indirect
discharges (after percolation
through soil or subsoil) of
pollutants into groundwater
http://eur-
lex.europa.eu/legal
-
content/EN/TXT/?ur
i=celex%3A32006L
0118
finishing processes
- surface treatment
supporting
processes -
wastewater
treatment
water (discharge)
emissions to
AIR
2001/379/
EC19
The aim of the Protocol is to
reduce emissions from heavy
metals caused by anthropogenic
activities that are subject to
long-range transboundary
atmospheric transport and are
likely to have serious adverse
effects on human health and the
environment. To this end, it
http://eur-
lex.europa.eu/legal
-
content/EN/TXT/?ur
i=CELEX:32001D03
79
manufacturing
processes
air (emission of
heavy metals)
18 Directive 2006/118/EC of the European Parliament and of the Council of 12 December 2006 on the protection of groundwater against pollution and deterioration 19 Council Decision 2001/379/EC of 4 April 2001 on the approval, on behalf of the European Community, of the Protocol to the 1979 Convention on Long-range
Transboundary Air Pollution on Heavy Metals
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 64
environmental
issues
reference short description of the field of
application
source link with Fabricated
Metal Products
activities (see
paragraph 1.3)
link with
environmental
parameters
stipulates the reduction of total
annual emissions into the
atmosphere of cadmium, lead
and mercury, and the application
of product control measures.
2001/81/E
C20
This Directive covers emissions
in the territory of the Member
States and their exclusive
economic zones from four
pollutants which arise as a result
of human activities: SO2, NOx,
VOC, NH3
http://eur-
lex.europa.eu/legal
-
content/NL/TXT/?ur
i=CELEX:32001L00
81
manufacturing
processes
air (emissions of
sulphur dioxide,
nitrogen oxides,
volatile organic
compounds and
ammonia)
2003/87/E
C21
This European emission trading
system (ETS) is the key measure
in European climate policy. It
covers more than 10.000
installations of energy-intensive
industry and electricity sector
that are responsible for almost
have of CO2-emissions in the EU.
http://eur-
lex.europa.eu/legal
-
content/EN/TXT/?ur
i=CELEX:02003L00
87-20140430
manufacturing
processes
emission of
greenhouse gases
20 Directive 2001/81/EC of the European Parliament and of the Council of 23 October 2001 on national emission ceilings for certain atmospheric pollutants 21 Directive 2003/87/EC of the European Parliament and of the Council of 13 October 2003 establishing a scheme for greenhouse gas emission allowance trading
within the Community and amending Council Directive 96/61/EC
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 65
environmental
issues
reference short description of the field of
application
source link with Fabricated
Metal Products
activities (see
paragraph 1.3)
link with
environmental
parameters
A company within the scope of
ETS (>3MW, listed in activities of
annex 1) needs to monitor and
report annually the CO2
emissions and is obliged to hand
in an amount of emission rights
corresponding with the amount
of CO2- emissions of the
previous year
NOISE 2000/14/E
C22
This framework Directive
harmonises the 9 existing legal
instruments on noise emissions
for each type of construction
plant and equipment, as well as
a directive on lawnmowers. The
aim is to improve the control of
noise emissions by more than
50 types of equipment used
outdoors, such as compressors,
excavator-loaders, different
types of saws, mixers, etc.
(Annex I).
http://eur-
lex.europa.eu/legal
-
content/NL/TXT/?ur
i=celex:32000L001
4
use phase noise
22 Directive 2000/14/EC of the European Parliament and of the Council of 8 May 2000 on the approximation of the laws of the Member States relating to the noise
emission in the environment by equipment for use outdoors
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 66
environmental
issues
reference short description of the field of
application
source link with Fabricated
Metal Products
activities (see
paragraph 1.3)
link with
environmental
parameters
WASTE Waste
Framework
Directive
(2008/98/
EC23)
This Directive repealed Directive
2006/12/EC of the European
Parliament and of the Council of
5 April 2006 on waste (the
codified version of Directive
75/442/EEC as amended),
hazardous waste Directive
91/689/EEC, and the Waste Oils
Directive 75/439/EEC. It
provides for a general framework
of waste management
requirements and sets the basic
waste management definitions
for the EU
http://ec.europa.eu
/environment/wast
e/legislation/a.htm
process design -
manufacturing
processes (all)
waste (hazardous /
non-hazardous)
WEEE
(2012/19/
EU24)
This Directive lays down
measures to protect the
environment and human health
by preventing or reducing the
adverse impacts of the
generation and management of
waste from electrical and
electronic equipment (WEEE) and
by reducing overall impacts of
http://ec.europa.eu
/environment/wast
e/weee/legis_en.ht
m
market processes -
material recycling
waste (hazardous /
non-hazardous)
23 Directive 2008/98/EC of the European Parliament and of the Council of 19 November 2008 on waste and repealing certain Directives
24 Directive 2012/19/EU of the European Parliament and of the Council of 4 July 2012 on waste electrical and electronic equipment (WEEE)
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 67
environmental
issues
reference short description of the field of
application
source link with Fabricated
Metal Products
activities (see
paragraph 1.3)
link with
environmental
parameters
resource use and improving the
efficiency of such use in
accordance with Articles 1 and 4
of Directive 2008/98/EC, thereby
contributing to sustainable
development
2002/95/E
C25
The purpose of this Directive is
to approximate the laws of the
Member States on the
restrictions of the use of
hazardous substances in
electrical and electronic
equipment and to contribute to
the protection of human health
and the environmentally sound
recovery and disposal of waste
electrical and electronic
equipment.
http://eur-
lex.europa.eu/legal
-
content/EN/TXT/?ur
i=CELEX:32002L00
95
upstream activities waste (hazardous)
25 Directive 2002/95/EC of the European Parliament and of the Council of 27 January 2003 on the restriction of the use of certain hazardous substances in electrical
and electronic equipment (ROHS)
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 68
environmental
issues
reference short description of the field of
application
source link with Fabricated
Metal Products
activities (see
paragraph 1.3)
link with
environmental
parameters
94/62/EC26 This Directive provides for
measures aimed at limiting the
production of packaging waste
and promoting recycling, re-use
and other forms of waste
recovery. Their final disposal
should be considered as a last
resort solution. This Directive
covers all packaging placed on
the European market and all
packaging waste, whether it is
used or released at industrial,
commercial, office, shop, service,
household or any other level,
regardless of the material used.
http://eur-
lex.europa.eu/legal
-
content/EN/TXT/?ur
i=CELEX:31994L00
62
downstream
manufacturing
waste (protection
packaging)
850/2004/
EC27
The objective of this Regulation
is to protect human health and
the environment from persistent
organic pollutants by prohibiting,
phasing out as soon as possible,
or restricting the production,
placing on the market and use of
substances subject to the
Stockholm Convention on
http://eur-
lex.europa.eu/legal
-
content/EN/TXT/?ur
i=CELEX:32004R08
50&qid=14252939
45113
manufacturing
processes
waste (hazardous)
26 Directive 94/62/EC of the European Parliament and Council of 20 December 1994 on packaging and packaging waste 27 Regulation (EC) No 850/2004 of the European Parliament and of the Council of 29 April 2004 on persistent organic pollutants and amending Directive 79/117/EEC
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 69
environmental
issues
reference short description of the field of
application
source link with Fabricated
Metal Products
activities (see
paragraph 1.3)
link with
environmental
parameters
Persistent Organic Pollutants, or
the 1998 Protocol to the 1979
Convention on Long-Range
Transboundary Air Pollution on
Persistent Organic Pollutants,
and by minimizing, with a view
to eliminating where feasible as
soon as possible, releases of
such substances, and by
establishing provisions regarding
waste consisting of, containing or
contaminated by any of these
substances.
333/2011/
EC
The criteria determining when
iron, steel and aluminium scrap
cease to be waste should ensure
that iron, steel and aluminium
scrap resulting from a recovery
operation meet the technical
requirements of the metal
producing industry, comply with
existing legislation and standards
applicable to products and do not
lead to overall adverse
environmental or human health
impacts.
http://eur-
lex.europa.eu/legal
-
content/EN/ALL/?ur
i=CELEX:32011R03
33&qid=14248561
34440
manufacturing
processes
waste
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 70
Remark
EU legislation regarding the environmental aspects RAW MATERIALS and ODOUR linked to the NACE 25 subsectors was not found.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 71
Table 12. Overview of the policy instruments relevant for products and processes of the NACE 25 (sub)sectors
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
OSPAR
Recommendation 98/1
concerning Best
Available Techniques
and Best Environmental
Practice for the Primary
Non-Ferrous Metal
Industry (Zinc, Copper,
Lead and Nickel Works)
This Recommendation
applies to the primary
metallurgical industry
producing one or more
of the following metals
or process related
compounds: zinc,
copper, lead or nickel.
http://rod.eione
t.europa.eu/obli
gations/584
upstream activities -
raw material
production
supporting processes -
air / wastewater
treatment
air / water
raw materials
BREF NFM
OSPAR
Recommendation 98/2
on Emission and
Discharge Limit Values
for Existing Aluminium
Electrolysis Plants
This Recommendation
covers emissions and
discharges from existing
aluminium electrolysis
plants, but does not
apply to anode baking
operations.
http://www.osp
ar.org/v_measu
res/browse.asp
?menu=010703
04570124_000
001_000000
upstream activities -
raw material
production
air (PAH & fluorides),
water (PAH)
BREF NFM
PARCOM
Recommendation 96/1
on Best Available
Techniques and Best
Environmental Practice
for Existing Aluminium
Electrolysis Plants
This Recommendation
covers emissions and
discharges from the
aluminium electrolysis
process, limited to pot-
room operations. This
Recommendation
applies to existing
plants only.
http://rod.eione
t.europa.eu/obli
gations/480
upstream activities -
raw material
production
raw materials BREF NFM
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 72
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
PARCOM
Recommendation 94/1
on Best Available
Techniques for New
Aluminium Electrolysis
Plants
The objective of this
Recommendation
prevents pollution of the
environment, arising
from emissions of
gaseous and liquid
pollutants from
aluminium electrolysis
in new installations, also
accounting for human
health.
http://rod.eione
t.europa.eu/obli
gations/498
upstream activities -
raw material
production
supporting processes -
air
PAH & fluorides BREF NFM
PARCOM Decision 96/1
on the Phasing-Out of
the Use of
Hexachloroethane in
the Non-Ferrous Metal
Industry
All uses of HCE in the
aluminium industry
(including integrated
and non-integrated
foundries casting
aluminium) shall be
phased out as far as
possible by
31 December 1996 and
at the latest by
31 December 1997. All
uses of HCE in other
non-ferrous metal
industry shall be phased
out by 31 December
1997
http://www.osp
ar.org/v_measu
res/browse.asp
?menu=010703
04570124_000
001_000000
upstream activities -
raw material
production
raw materials BREF NFM
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 73
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
PARCOM
Recommendation 92/1
on best available
technology for plants
producing anodes and
for new electrolysis
installations in the
primary aluminium
industry
Best Available
Technology in new
electrolysis plants and
in existing plants which
increase capacity by
installing new cells,
should be based on the
use of pre-baked
anodes
http://www.osp
ar.org/v_measu
res/browse.asp
?menu=010703
04570124_000
001_000000
upstream activities -
raw material
production
raw materials BREF NFM
PARCOM
Recommendation 92/2
Concerning Limitation
of Pollution from New
Primary Iron and Steel
Production Installations
The recommendation
applies for new and
substantially modified
primary iron and steel
production installations
that have been granted
a building licence after 1
January 1993. The
recommendation
contains two general
requirements. For
processes where this
general approach should
be either specified or
modified, separate
requirements are given.
http://rod.eione
t.europa.eu/obli
gations/469
upstream activities -
raw material
production
raw materials BREF FMP
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 74
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
PARCOM
Recommendation 92/3
Concerning Limitation
of Pollution from New
Secondary Steel
Production and Rolling
Mills
EQS to water
(suspended solids, oil,
metals) for continuous
casting and hot rolling &
air
http://rod.eione
t.europa.eu/obli
gations/496
upstream activities -
raw material
production
raw materials BREF FMP
OSPAR
Recommendation
2002/1 on Discharge
Limit Values for Existing
Aluminium Electrolysis
Plants
This Recommendation
covers discharges to
water from existing
aluminium electrolysis
plants and does not
apply to anode-baking
operations. This
Recommendation
supplements OSPAR
Recommendation 98/2
http://rod.eione
t.europa.eu/obli
gations/489
upstream activities -
raw material
production
water (discharge) - 6
PAH components
(Fluoranthene,
Benzo(k)fluoranthene
,
Benzo(b)fluoranthene
, Indeno(1,2,3-
cd)pyrene,
Benzo(a)pyrene,
Benzo(ghi)perylene)
BREF STM
PARCOM
Recommendation 84/2
for reducing cadmium
pollution
Reducing cadmium from
electroplating
http://www.osp
ar.org/v_measu
res/browse.asp
?menu=010703
04570124_000
001_000000
outdated - very
general
recommendations
BREF STM
Table 13. Overview of the best practice guidance relevant for products and processes of the NACE 25 (sub)sectors
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 75
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
Best practices for
planning in the metals
industry
A high level of
inefficiency is related to
the production planning
processes in the metals
industry. Low asset
utilization, poor delivery
performance and high
inventory carryover are
the three key areas of
inefficiency.
Corresponding Key
Performance Indicators
in these three areas are
typically used in order
to measure and improve
production planning
performance.
http://www.opti
malcore.com/th
e-core-blog/58-
best-practices-
for-planning-in-
the-metals-
industry.html
logistics, handling and
storage
resource use;
emissions
BREF STM
Best Practices for
Fabricated Metals
Developed for small and
midsize companies to
implement a solution
quickly and easily;
Production planning and
control, Materials
management, Sales and
distribution, Logistics
General QM/PLM,
Accounting, Controlling,
Master Data Generation,
(hard copy) logistics, handling and
storage
resource use;
emissions
BREF STM
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 76
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
Forms and reporting,
Non-Ferrous Metal
Pricing in DIMP system
The Surface Treatment
of Metals and Plastics
by Electrolytic and
Chemical Processes
(EPR 2.07)
sector guidance note
(will be reviewed in the
light of future BREF
note revisions)
finishing processes -
surface treatment
resource use (all),
emissions (all), waste
(all)
BREF STM
Metalworking Fluids:
Safety and Health Best
Practices Manual
This document on best
practices was developed
using the
recommendations set
forth in the OSHA
Metalworking Fluids
Standards Advisory
Committee Final Report
(1999); the NIOSH
Criteria Document on
Occupational Exposure
to Metalworking Fluids
(1998); and the
Organization Resources
Counsellors,
"Management of the
Metal Removal Fluid
Environment: A Guide
https://www.os
ha.gov/SLTC/m
etalworkingfluid
s/metalworking
fluids_manual.h
tml
supporting processes -
manufacturing
processes
consumables /
chemicals
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 77
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
to the Safe and Efficient
Use of Metal Removal
Fluids" (1999)
MIG Welding
Aluminium: Important
Questions and Best
Practices
- filler metal selection
- filler metal storage
- wire feeding options
- short-circuit, spray
transfer or pulsed MIG
http://www.mill
erwelds.com/re
sources/articles
/MIG-GMAW-
Effective-on-
Aluminum/
raw materials consumables
Sector Specific Best
Practice Guide Best
Practices in metal
plating and finishing
This guide is aimed at
the smaller metal
finishers and mainly
focuses on
environmental best
practices that are
relatively simple and
straightforward to
implement in an
existing facility.
Therefore some of the
more expensive best
practice options (e.g.,
electrodialysis to
concentrate drag-out;
ultrafiltration for
process bath
maintenance, etc.) have
been omitted from this
http://enviroce
ntre.ie/Content.
aspx?ID=97861
425-c328-
4b1b-aa3f-
472ca8e3d759
&PID=a257bec
e-c1e7-464a-
9cd0-
fde10d3a18c3#
Metal
finishing processes -
surface treatment
resource use (all),
emissions (all), waste
(all)
BREF STM
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 78
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
guide.
Guide to good
manufacturing and
hygiene practices for
metal packaging in
contact with food
This guide of
recommended good
hygiene and
manufacturing practices
applies to the
manufacture of steel for
packaging intended to
come into contact with
foodstuffs
http://www.goo
gle.be/url?sa=t
&rct=j&q=&esr
c=s&source=we
b&cd=2&ved=0
CCcQFjAB&url=
http%3A%2F%
2Fwww.vet.agri
.ee%2Fstatic%
2Ffiles%2F705.
1.GM%26HP_Fi
nal_2009.pdf&e
i=oOr-
VMbDKKqd7Abo
7YGgDw&usg=
AFQjCNHFywLG
aM76w09YSk2q
ELPaZ-
oE0A&bvm=bv.
87611401,d.ZG
U
design process material selection
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 79
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
CETS (2002), Reference
document on best
available techniques for
the surface treatment
of plastic and metals
using electrolytic or
chemical process
see BREF STM finishing processes -
surface treatment
BREF STM
CETS (2001), Reference
Document on best
available techniques
Surface Treatment of
metals and plastic
materials using
electrolytic or chemical
process (volume of
treatment vats > 30
m3)
see BREF STM finishing processes -
surface treatment
BREF STM
Nordic-Council (2002),
DEA- an aid for
identification of BAT in
the inorganic surface
treatment industry &
Environmentally
acceptable
The report describes the
latest technical
developments and
presents the results of a
new benchmarking
method to identify BAT
and the possibilities of
finishing processes -
surface treatment
BREF STM
and BREF
STS
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 80
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
metalworking processes reducing environmental
impacts from surface
treatment
BAT and Cleaner
technology in
environmental permits -
part 2: surface
treatment (2009)
The overall aim of the
project is to ensure that
the Nordic industry is
producing according to
technologies and
methods that lead to
the lowest possible
impact on the
environment. This
overall aim should be
achieved through
formulation of
conditions in
environmental permits
and licenses which are
as uniform as possible1
within the various
industrial sectors. The
immediate aim is to
elaborate an easy-to-
use tool for Nordic
environmental
authorities providing
http://www.goo
gle.be/url?sa=t
&rct=j&q=&esr
c=s&frm=1&so
urce=web&cd=
8&cad=rja&uac
t=8&ved=0CEQ
QFjAH&url=http
%3A%2F%2Fn
orden.diva-
portal.org%2Fs
mash%2Fget%
2Fdiva2%3A70
0592%2FFULLT
EXT01.pdf&ei=
aEDvVIeYAoXW
apK5gqgO&usg
=AFQjCNE6Gp_
aZ2ZAlYy_pjf19
WVamxc4pg
finishing processes -
surface treatment
BREF STM
and BREF
STS
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 81
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
them with guidance,
and to get an overview
of practices used by
Nordic colleagues and
an overview of the
Nordic experience
concerning terms, BAT
and CT.
UNEP; MAP and RAC/CP
(2002), Alternatives for
preventing pollution in
the surface treatment
industry
The objective of this
study is to present the
options for pollution
prevention at source
which could be
implemented in
Mediterranean
industries of this sector
within the various
processing stages
(washing, degreasing,
pickling, metallic
coating, etc.)
http://www.une
pmap.org/index
.php?s_sort=titl
e&module=libra
ry&mode=pub&
action=results&
s_category=&s
_keywords=&s_
title=&s_year=
&page=&s_des
criptors=Surfac
e+treatment+i
ndustry&s_auth
or=&s_type=&s
_final=&s_mnu
mber=
finishing processes -
surface treatment
BREF STM
and BREF
STS
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 82
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
pollution prevention in
the metal machining
industry (2005)
The principal objective
of this manual is to
inform enterprises
working in the metal
machining sector of the
opportunities available
to them for integrated
pollution prevention. In
this way they can
foresee, and minimize,
the environmental
impact of their activity,
while at the same time
they can be encouraged
to look into new ways of
preventing pollution in
their factories.
This manual is divided
into six sections:
Introduction, Processes,
Environmental Aspects,
Pollution prevention and
reduction opportunities,
Practical case studies
and Conclusions.
http://www.cpr
ac.org/en/medi
a/studies/secto
r-
studies?page=1
forming processes
(e.g. bending);
finishing processes -
heat treatment
BREF FMP
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 83
reference short description of the
field of application
source link with Fabricated
Metal Products
activities (see §1.3)
link with
environmental issues
covered by
Pollution Prevention for
the Electroplating and
Metal Finishing Industry
(Kansas Small Business
Environmental
Assistance Program)
The document covers
pollution prevention
strategies that can be
implemented to
minimize the generation
and release of wastes.
The manual introduces
pollution prevention
concepts applied to
common processes,
gives an overview of
some of the alternative
technologies available
to minimize pollution,
and briefly discusses
regulatory requirements
in the state of Kansas.
Case studies and
success stories from
shops using these
technologies are
included to show how
others have reduced
their waste streams and
their regulatory
requirements
Metal Finishing
& Pollution
Prevention
finishing processes -
surface treatment
waste (hazardous) BREF STM
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1.6. Scope of the proposed best environmental management practice
in the Fabricated Metal Product manufacturing sector
BEMPs aim at improving the environmental performance of companies, taking into
account the relevant direct and indirect environmental impacts of the production
processes and of the entire value chain of the Fabricated Metal Product manufacturing
sector. To reach a high level of effectiveness, the BEMPs must be selected focusing on
the areas of the value chain having a high environmental pressure. To ensure policy
coherence, the BEMPs must be complementary to the existing EU legislation, policy
instruments and best practice guidance.
Therefore the analysis of the data in the previous paragraphs on economics (§1.2),
environmental aspects and pressures (§1.3) and on EU legislation, policy instruments
and best practice guidance (§1.5) have to be combined in order to identify the scope
of this study.
Environmental impact
There is no specific EU legislation or policy instruments which stimulates or obligates
the sector directly to change or reduce their material uses. However, the use of
materials is one of the main environmental aspects of the whole Fabricated Metal
Products sector.
The main impact is located upstream, in the production of ferrous and non-ferrous
metals. In the Fabricated Metal Products sector, the removing processes cause the
highest impact on the use of materials. In the downstream activities, also high
amounts of material are used (e.g. metal structures in building materials).
The direct emissions of the upstream value chain are covered by the BREF NFM and
BREF FMP. But by focusing on concurrent engineering in the Fabricated Metal Products
sector, the material use upstream will reduce.
The Fabricated Metal Products sector is an energy intensive sector, where the utilities
in the supporting processes are responsible for the high energy use. The Energy
efficiency directive (2012/27/EU) and the BREF ENE give companies an incentive to
reduce the use of primary energy. For the other energy intensive process steps, like
forming, removing and additive process, there are no specific policy instruments to
trigger the companies to reduce their energy use. The energy uses in the upstream
processes and in the finishing processes are covered by the BREFs NFM, BREF FMP,
BREF STS and BREF STM.
In general, the sector is less impactful in terms of water use. Only the finishing
processes are important consumers of water, and these aspects are covered by the
BREF STS and STM.
In the Fabricated Metal Products sector different auxiliary materials are used in the
production process. The removing, joining and finishing processes are characterized
by the highest use of consumables. In case of chemicals, the environmental aspects
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of these products are regulated by REACH. For other types of auxiliary materials, there
are no specific legislation or policy instruments for the Fabricated Metal Products
sector.
As resource use is important for the sector, the BEMPs will focus on this topic. Priority
will be given to practices in the Fabricated Metal Products sector, with a positive effect
on the upstream and downstream value chain and to the forming, removing, additive
and joining processes in the sector. Less attention will be given to the utilities and
finishing processes, since there are already documents (BREFs), legislation and policy
instruments to control this impact.
Emissions
The finishing processes cause the highest direct emissions in the Fabricated Metal
Products sector, especially to water. The latter cause a negative impact on the
internal waste water treatment plants. The emissions of these activities are regulated
in the IED (2010/75/EC), and are subject of the BREF STS and BREF STM.
Other emissions (to air, odour, noise and vibrations) can be found in the joining,
forming and removing processes. For each of these emissions, there is general
legislation (2001/379/EC; 2001/81/EC; 2003/87/EC and 2000/14/EC(3)) to control or
regulate the impact. But none of these is specific for the sector.
With exception of the finishing processes, which are covered by the BREF, all
manufacturing processes of the Fabricated Metal Products sector are subject for
BEMPs to reduce the impact.
The indirect emissions caused upstream in the value chain, can only be influenced by
the Fabricated Metal Products sector when the sector itself uses less materials. This
will be studied under the BEMPs for resource use.
Waste
Most of the waste in the sector is generated in the removing processes. The waste
produced is non-hazardous waste and must be seen as left overs of materials. The
solutions of these problems are linked with the success of a better material use.
The finishing processes are the main source of hazardous waste and liquid waste.
These processes are subject to legislation (IED, 850/2004) and the BREFs STS and
STM.
Subsectors in the Fabricated Metal Products sector
Based on Table 7, which describes the direct and total emissions and resource use of
the Fabricated Metal Products subsectors, as well as Figure 5, which gives a view on
the relative share of turnover for the different subsectors, and based on the expert
judgment of the consortium, we conclude that:
The types of processes applied do not significantly differ depending on the
subsectors. Similar processes and activities are used in the entire Fabricated
Metal Products sector, like logistics, utilities and manufacturing processes (e.g.
removing forming, additive processes). There are no clear indications of
Background document on best environmental management practice in the Fabricated Metal Products sector
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important differences between the subsectors in terms of processes and
activities;
There is a direct link between the economic importance of a subsector (the
turnover) and almost all studied direct emission and resource use. NACE 25.1
(manufacture of structural metal products) followed by NACE 25.9
(manufacture of other fabricated metal products) and NACE 25.6 (treatment
and coating of metals and machining) are the economically and
environmentally most important subsectors;
Only the direct emissions (and consequently linked the total emissions) of
NMVOC do not follow this logic. NACE 25.1, emits half of the NMVOC of the
NACE 25.9 while both are economically similar. One can say that the NACE
25.1 subsector controls its emissions of NMVOC better than other subsectors.
In general, however, we conclude that the processes, the emissions and resource use
are comparable in all subsectors. Therefore, the BEMPs will be defined on the level of
the entire NACE 25 sector. As explained under §1.1 (Composition of the Fabricated
Metal Products sector) the manufacturing and supporting activities of the NACE 25
sector are also common used within other sectors. By defining the BEMPs we will focus
on these activities, rather than on the entire NACE division 25.
Scope at activity level
Supporting processes:
o Management, procurement, supply chain management, quality control;
o Utilities and maintenance.
Manufacturing processes (red border line in Figure 9 and Figure 10):
o Forming processes;
o Removing processes;
o Additive processes;
o Joining processes;
o Finishing processes.
Scope on organizational level (red border line in Figure 6):
o Product design;
o Concurrent engineering.
Logistics, handling and storage will be out of the scope since these activities are
comparable with all production industries that make semimanufactured or end
products.
Emission treatment is out of the scope. By defining the BEMPs we give priority to
reduce the environmental impact and improving the environmental performance by
using the first steps of the sustainability principles of as defined under the Trias
energetica (Box 2), the Lansink’s ladder (Box 3) and under the IED (Box 4).Emission
control is always the last step along these principles.
Following the principles of the circular economy, there is no waste / emission, because
the by-products become raw materials for new products (Box 5).
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Box 2. Trias energetica
Trias energetica was defined by the
University of Delft for the built environment.
The concept helps to achieve energy savings,
reduce our dependence on fossil fuels, and
save the environment.
The 3 elements of Trias Energetica are:
1. Reduce the demand for energy by
avoiding waste and implementing energy-
saving measures;
2. Use sustainable sources of energy like
wind, the sun, water and the ground;
3. Use fossil fuel energy as efficiently as
possible and only if sustainable sources of
energy are unavailable.
In addition, try to compensate the damage
you do to the environment by compensating
your pollution by doing good things like
planting trees.
Box 3. Lansink’s ladder
The Lansink’s ladder is an order of preference on how to manage waste. It was
conceived in 1979 by the Dutch politician Ad Lansink and consists of the following
steps:
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Box 4. Principles of Article 11 of the IED (General principles governing the basic
obligations of the operator)
Member States shall take the necessary measures to provide that installations are
operated in accordance with the following principles:
(a) all the appropriate preventive measures are taken against pollution;
(b) the best available techniques are applied;
(c) no significant pollution is caused;
(d) the generation of waste is prevented in accordance with Directive
2008/98/EC;
(e) where waste is generated, it is, in order of priority and in accordance with
Directive 2008/98/EC, prepared for re-use, recycled, recovered or, where that is
technically and economically impossible, it is disposed of while avoiding or reducing
any impact on the environment;
(f) energy is used efficiently;
(g) the necessary measures are taken to prevent accidents and limit their
consequences;
(h) the necessary measures are taken upon definitive cessation of activities to
avoid any risk of pollution and return the site of operation to the satisfactory state
defined in accordance with Article 22.
in general one can split up the actions in three main stages:
- Prevention of emissions;
- Reduction of emissions;
- Control of emissions.
Box 5. The circular economy principle (Ellen MacArthur foundation, 2013; EU, 2014)
1. Circular economy is a global economic model that decouples economic growth
and development from the consumption of finite resources;
2. Distinguishes between and separates technical and biological materials,
keeping them at their highest value at all times;
3. Focuses on effective design and use of materials to optimize their flow and
maintain or increase technical and natural resource stocks;
4. Provides new opportunities for innovation across fields such as product design,
service and business models, food, farming, biological feedstocks and
products;
5. Establishes a framework and building blocks for a resilient system able to work
in the longer term.
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References
Allwood, J.M., Cullen, J.M., Carruth, M.A., Cooper, D.R., McBrien, M., Milford, R.L.,
Moynihan, M., Patel, A.C.H. (2012) Sustainable materials: with both eyes open. UIT,
Cambridge. ISBN 978-1-906860-05-9, available online at:
http://www.withbotheyesopen.com/, last accessed on 13th April 2015.
Bras B. Incorporating Environmental Issues in Product Realization. Industry and
Environment, United Nations UNEP/IE (invited contribution), Vol. 20, No. 1-2 (double
issue), pp. 7-13, available online at:
http://www.engineering.dartmouth.edu/~d30345d/courses/engs171/Bras-1997.pdf,
last accessed on 13th April 2015.
Coulter, S., Bras, B. A. and Foley, C., 1995, "A Lexicon of Green Engineering Terms,"
10th International Conference on Engineering Design (ICED 95), Praha, Czech
Republic, Heurista, Zurich, Switzerland, pp. 1033-1039.
Ellen MacArthur Foundation, 2013. Towards the circular economy: Opportunities for
the Consumer Goods Sector, Vol. 2.
ESA, 2012, What is concurrent engineering, available online at:
http://www.esa.int/Our_Activities/Space_Engineering_Technology/CDF/What_is_conc
urrent_engineering, last accessed on 13th April 2015.
EU, 2014, Scoping study to identify potential circular economy actions, priority
sectors, material flows and value chains, available online at:
http://bookshop.europa.eu/en/scoping-study-to-identify-potential-circular-economy-
actions-priority-sectors-material-flows-and-value-chains-
pbKH0114775/?CatalogCategoryID=h2YKABstrXcAAAEjXJEY4e5L, last accessed on
13th April 2015.
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http://ec.europa.eu/eurostat/web/structural-business-statistics/overview, last
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Eurostat, 2013. Manufacture of fabricated metal products statistics - NACE Rev. 2
(Division 25), available online at:
http://ec.europa.eu/eurostat/statistics-
explained/index.php/Manufacture_of_fabricated_metal_products_statistics_-
_NACE_Rev._2, last accessed on 13th April 2015.
Fraunhofer IZM, 2012. Energy-Using Product Group Analysis - Lot 5. Machine tools
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http://www.wellmet2050.com, last accessed on 13th April 2015.
Winner, R. I., Pennell, J. P., Bertrand, H. E. and Slusarczuk, M. M. G., 1988, "The Role
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2015.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 91
CHAPTER 2. Best environmental management practice
2.1. Technique portfolio
The list of proposed BEMPs for the Fabricated Metal Products sector are a range of
possibilities for companies to improve their environmental performance. Some of the
BEMPs will reduce the raw and auxiliary material or energy use in the Fabricated Metal
Products sector, while others will have a main impact upstream or downstream (direct
versus indirect effects). In most of the cases, there is an impact on different
environmental aspects in different places in the value chain.
The following two tables (Table 14 and Table 15) present how the most relevant
environmental aspects and the related main environmental pressures are addressed,
either in this document or in other the Best Available Techniques Reference
Documents28. For the aspects covered in this document, the tables mention the best
environmental management practices (BEMPs) to address these.
28 Other relevant sources of information are listed in paragraph 1.5. These include EU
legislation, policy instruments and best practice guidance.
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Table 14. Most relevant direct environmental aspects for the Fabricated Metal Products companies how these are addressed
Most relevant direct
environmental aspects
Related main environmental
pressures
BREF BEMPs
Supporting processes
Management, procurement,
supply chain management,
quality control
Raw materials use
Energy use
Consumables use
Water use
2.2.1 Extend the lean principles with measures for energy and material
consumption
2.2.2 Measures for stock reduction - while keeping customer
demand flexibility
2.2.3 Cross-sectoral and value chain collaboration (by communication
and integration)
2.2.4 Chemical leasing & Chemical management services
2.4.2 Co-design and open innovation with downstream partners to reduce
environmental impact during product life cycle
Utilities and maintenance Energy use
Water use
Consumables use
Emissions to water
Odour
Other emissions (noise, vibration)
STM
STS
ENE
ICS
2.2.5 Energy management
2.2.6 Efficient ventilation
2.2.7 Optimal lighting
2.2.8 Energy and water savings of cooling circuits
2.2.9 Efficient use of compressed air systems
2.2.10 Reduction of standby energy of metal working machines
2.3.3 Selection of coolant as environmental and performance
criterion
2.3.9 Reduce the energy for paint booth HVAC with predictive control
2.3.10 Selection and optimization of thermal processes for curing wet-
chemical coatings on metal products
Manufacturing
processes
Forming processes Raw materials use 2.2.1 Extend the lean principles with measures for energy and material
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Most relevant direct
environmental aspects
Related main environmental
pressures
BREF BEMPs
Energy use
Other emissions (noise, vibration)
Non-hazardous waste
consumption
2.2.6 Efficient ventilation
2.2.8 Energy and water savings of cooling circuits
2.2.10 Reduction of standby energy of metal working machines
2.3.1 Application of solid low-friction coatings on tools and components
2.3.2 Application of wear- and corrosion-resistant coatings of tools and
equipment
2.3.3 Selection of coolant as environmental and performance
criterion
2.3.4 Incremental Sheet metal Forming (ISF) as alternative for mould
making
2.3.5 Additive manufacturing of complex equipment - flow optimization
for optimal heat transfer and temperature control
2.3.6 Multi-directional forging: a resource efficient metal forming
alternative
2.3.7 Hybrid machining as a method to reduce energy consumption
Removing processes Raw materials use
Energy use
Consumables use
Water use
Emissions to water, air, odour
Non-hazardous waste
Liquid waste
2.2.1 Extend the lean principles with measures for energy and material
consumption
2.2.6 Efficient ventilation
2.2.8 Energy and water savings of cooling circuits
2.2.10 Reduction of standby energy of metal working machines
2.3.1 Application of solid low-friction coatings on tools and components
2.3.2 Application of wear- and corrosion-resistant coatings of tools and
equipment
2.3.3 Selection of coolant as environmental and performance
criterion
2.3.7 Hybrid machining as a method to reduce energy consumption
2.3.8 Machining of near-net-shape feedstock
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Most relevant direct
environmental aspects
Related main environmental
pressures
BREF BEMPs
Additive processes Raw materials use
Energy use
Other emissions (noise, vibration)
Non-hazardous waste
2.2.1 Extend the lean principles with measures for energy and material
consumption
2.2.6 Efficient ventilation
2.2.8 Energy and water savings of cooling circuits
2.2.10 Reduction of standby energy of metal working machines
2.3.3 Selection of coolant as environmental and performance
criterion
2.3.5 Additive manufacturing of complex equipment - flow optimization
for optimal heat transfer and temperature control
2.3.7 Hybrid machining as a method to reduce energy consumption
2.3.8 Machining of near-net-shape feedstock
Joining processes Energy use
Consumables use
Raw materials use
Emissions to air, odour
Other emissions (noise, vibration)
Non-hazardous waste
2.2.1 Extend the lean principles with measures for energy and material
consumption
2.2.4 Chemical leasing & Chemical management services
2.2.6 Efficient ventilation
2.2.8 Energy and water savings of cooling circuits
2.2.10 Reduction of standby energy of metal working machines
2.3.3 Selection of coolant as environmental and performance
criterion
2.3.7 Hybrid machining as a method to reduce energy consumption
Finishing processes Water use
Energy use
Consumables use
Raw materials use
Emissions to water, air, odour
Hazardous, non-hazardous and
STM
STS
2.2.1 Extend the lean principles with measures for energy and material
consumption
2.2.4 Chemical leasing & Chemical management services
2.2.6 Efficient ventilation
2.2.8 Energy and water savings of cooling circuits
2.2.10 Reduction of standby energy of metal working machines
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Most relevant direct
environmental aspects
Related main environmental
pressures
BREF BEMPs
liquid waste 2.3.1 Application of solid low-friction coatings on tools and components
2.3.2 Application of wear- and corrosion-resistant coatings of tools and
equipment
2.3.3 Selection of coolant as environmental and performance
criterion
2.3.7 Hybrid machining as a method to reduce energy consumption
2.3.9 Reduce the energy for paint booth HVAC with predictive control
2.3.10 Selection and optimization of thermal processes for curing wet-
chemical coatings on metal products
Table 15. Most relevant indirect environmental aspects for the Fabricated Metal Products companies how these are addressed
Most relevant direct
environmental aspects
Related main environmental
pressures
BREF BEMPs
Upstream - Design
process
Raw material production
Product equipment
Raw materials use
Energy use
Consumables use
Water use
Emissions to water, air
Other emissions (noise,
vibration)
Hazardous, non-hazardous and
liquid waste
FMP
NFM
SF
ENE
LCP
2.2.3 Cross-sectoral and value chain collaboration (by communication
and integration)
2.2.4 Chemical leasing & Chemical management services
2.4.1 Remanufacturing of high value components
Downstream -
Manufacturing processes
Assembly
Product finishing
Raw materials use
Energy use
WT
WI
2.2.3 Cross-sectoral and value chain collaboration (by communication
and integration)
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Most relevant direct
environmental aspects
Related main environmental
pressures
BREF BEMPs
production and packaging
logistics
Noise
Non-hazardous waste
2.4.2 Co-design and open innovation with downstream partners to
reduce environmental impact during product life cycle
2.4.1 Remanufacturing of high value components
Value chain – Design
process
Material selection Raw materials use
Energy use
Consumables use
Water use
Non-hazardous
2.2.3 Cross-sectoral and value chain collaboration (by communication
and integration)
2.4.2 Co-design and open innovation with downstream partners to
reduce environmental impact during product life cycle
2.3.1 Application of solid low-friction coatings on tools and components
2.3.2 Application of wear- and corrosion-resistant coatings of tools and
equipment
2.3.5 Additive manufacturing of complex equipment - flow optimization
for optimal heat transfer and temperature control
Value chain – market
processes
Use Phase
Refurbishment
Disassembly
Material recycling
Other emissions (noise,
vibration)
Hazardous, non-hazardous waste
2.2.3 Cross-sectoral and value chain collaboration (by communication
and integration)
2.4.2 Co-design and open innovation with downstream partners to
reduce environmental impact during product life cycle
2.4.1 Remanufacturing of high value components
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2.2. Best environmental management practices for the supporting
processes
The proposed BEMPs for supporting processes are split up in BEMPs for Management,
procurement and supply chain management:
2.2.1 Extend the lean principles with measures for energy and material
consumption
2.2.2 Measures for stock reduction - while keeping customer demand flexibility
2.2.3 Cross-sectoral and value chain collaboration (by communication and
integration);
2.2.4 Chemical leasing & Chemical management services;
and BEMPs to optimize the utilities:
2.2.5 Energy management;
2.2.6 Efficient ventilation;
2.2.7 Optimal lighting;
2.2.8 Energy and water savings of cooling circuits;
2.2.9 Efficient use of compressed air systems
2.2.10 Reduction of standby energy of metal working machines
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2.2.1. Extend the lean principles with measures for energy and material
consumption
Description
Lean principles can be applied in companies in the Fabricated Metal Product
manufacturing sector to review and improve their production processes. The lean
principles are used to detect inefficiencies or waste. These types of waste can be of
various natures and often are divided in seven categories (Lean manufacturing tools,
2015):
- Overproduction;
- Waste of inventory;
- Waste of transportation;
- Waste of waiting;
- Production of defects;
- Waste of over-processing;
- Waste of unnecessary motion.
Important for companies in the sector is that all seven wastes cause energy and
possibly materials losses. However, this is something often overlooked and the savings
related to the implementation of lean principles are not properly quantified. Studies
suggest that energy use could be reduced in manufacturing and industrial sectors by
75% with the currently available technologies at little cost (Miller, 2009).
Overproduction leads to the consumption of energy by operating equipment to make
products which are not needed. This is related to the other types of wastes being
created, such as inventory which needs to be heated, cooled, conveyed and lighted
using all significant amounts of energy. Transportation of products uses more energy.
Waiting itself may not be the main category of waste, however, the light, heat and
running equipment consumes energy while people/staff are waiting. Defects during
production process use significant amounts of energy. All of the energy to
manufacture the products is wasted in case of defects since the products need to be
made again, and often people spend time correcting, reporting and analysing the
defect which uses energy in a variety of ways. Processing waste streams creates
energy losses when the equipment size and speed are inappropriate to get the job
done efficiently. Motion waste is the most challenging category to link with energy
waste because it relates to human motion. Excessive human motion can cause unsafe
work conditions, lower productivity or poor quality which has consequences on energy
efficiency.
These seven types of waste can be extended with two more types, relevant for the
Fabricated Metal Products sector: system integration/optimization and technological
improvements. Example for system integration and optimization are reuse of waste
heat between different processes, cascading waste water etc. The technological
improvements can highly impact investment decision especially if Total Cost of
Ownership (TCO) is a key criterion e.g. high efficiency pumps (evaluation of new pomp
motor versus frequency converters on old pump motors. These types of waste are
related to the application of specific systems or technologies. The waste of some
Background document on best environmental management practice in the Fabricated Metal Products sector
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technologies, e.g. produced heat, is often not efficiently applied in other technologies
or systems within company (see Figure 11).
Figure 11. Lean waste concept can be translated into energy terms and is
strengthened by two additional levers (http://www.mckinsey.com)
In order to implement lean principles in a company from the sector, the following five-
step process has to be taken into account (Cardiff University, 2015):
1. Identify customers and specify value: The starting point is to recognise that
only a small fraction of the total time and effort in any company actually adds
value for the end customer. By clearly defining value for a specific product or
service from the end customer’s perspective, all the non-value activities - or
waste - can be targeted for removal.
2. Identify and map the value stream: The value stream is the entire set of
activities across all parts of the company involved in jointly delivering the
product or service. This represents the end-to-end process that delivers the
value to the customer. Once it is understood what the customer want the next
step for a company is to identify how it can delivering (or not) that to them.
3. Create flow by eliminating waste: Typically when value stream is first mapped,
it is found that only 5% of activities add value (which can rise to 45% in a
service environment). Eliminating this waste ensures that the product or
service “flows” to the customer without any interruption, detour or waiting.
4. Respond to customer pull: This is about understanding the customer demand
on the service and then creating the process to respond to this. Such that a
company produces only what the customer wants when the customer wants it.
5. Pursue perfection: Creating flow and pull starts with radically reorganising
individual process steps, but the gains become truly significant as all the steps
link together. As this happens more and more layers of waste become visible
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and the process continues towards the theoretical end point of perfection,
where every asset and every action adds value for the end customer.
Figure 12. Five-step process for implementing lean principles in a company (Lean
Enterprise Institute, 2015)
A lot of the other BEMPs illustrated how the lean principles can be introduced in the
utilities and production steps.
Achieved environmental benefits
Effectively implementing lean principles in a company can lead to various
environmental benefits, all related to the specific production process. In the case of
the Fabricated Metal Products sector, the main environmental benefits is a reduction of
resource use, i.e. energy (and CO2-emissions) and materials. Significant reductions of
the waste streams and the amount of waste produced during manufacturing are
known as well.
Appropriate environmental indicators
Indicators for measuring performance of companies using the lean principles depend
on the production processes and materials, but in general this indicators give an
overall view on how companies are doing:
- kg raw material used per produced unit;
- total energy use per produced unit;
- kg waste produced per year or per product;
- % of the products which complain to the quality standards.
More specific, the indicators can give information on:
- Overproduction & waiting: Measure the energy needed to manufacture one
product kWh/product shipped. The energy use is in this case to be measured
for an entire production entity and over a fixed period of time;
- Transportation - Motion: Internal and external transport. Allocate the energy
use (e.g. gas, electric power of forklift truck) to sold production volumes.
(kWh/products shipped);
- Over specification: This can be over specification of process equipment like
compressed air (oil free, pressure, flow, etc.) which might be reduced without
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compromising the quality. Over specification of the manufactured product or
packaging can also lead to unrequired process steps. Finally also improved
process control can often eliminate the need product testing. Defining
test/inspection sample size in function of the number and type of detected
defects. Over specification can be tackled by qualitative measures like: Testing
and define the specification per process or operation.
- Inventory: If the indirect impact of inventory (Energy use for lighting, heating,
etc.) can be measured this can be used as an indicator e.g. kWh/products sold,
kWh/products made. (See also BEMP 2.2.2 on Measures for stock reduction -
while keeping customer demand flexibility);
- Rework/Scrap: Often the weight can be easily measured. (kg scrap per number
of products ). To associated lost energy is hard to allocate;
- Employee potential: Number of actions coming from shop floor employees
(suggested, reviewed and implemented);
- System: Here typical input output evaluations are set up. kWh heat used in
processes/ kWh heat dissipated through cooling. Water (rainwater, drink
water,…) used versus waste water treated or emitted;
- Technology: Having a technology watch for the processes with the highest
impact (energy use, material use, emission, etc.) makes it possible to review
the current processes with the best available technologies on a regular basis.
Cross-media effects
In order to optimally incorporate continuous improvement and strive for reductions in
resource use and waste production in a company, a mature lean manufacturing
system is required. Applying the lean principles and five-step process without an
overall lean management approach might lead to a suboptimal outcome and even
additional costs.
Operational data
Case study Toyota (Japan) – Tsutsumi plant, (Miller, 2009)
The lean principles were implemented in order to save energy and reduce waste as
well as to enhance eco-thinking and renewable energy systems. These measures have
contributed to Tsutsumi's overall CO2 emissions being cut by more than 50%since
1990 (ca. 150,000 tonnes). Furthermore, since Prius production began in 1997, the
plant has reduced the amount of waste going to landfill by 82% and has instituted
plans to achieve complete elimination of incinerated waste. Within Lean production
environments Value Stream Mapping/Method (VSM) is a used to identify the potential
of process improvements.
Fraunhofer proposed and implemented the principles of the Value Stream Method
(VSM) to analyse the energy use per process. It allows the companies familiar with the
well-proven VSM methodology to analyse the energy efficiency. Figure 13 gives an
overview of these principles
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Figure 13. Principles of the Value Stream Method (Franhofer, 2011)
The result of this analysis is a systemic procedure in three steps for (Figure 15):
1. Holistic collection and evaluation of energy consumption in production
processes;
2. Increasing energy efficiency by using design guidelines;
3. Finally optimization of energy consumption;
Typical approach in line with value stream mapping can be:
1) Identification and scope the process to investigate;
2) Identification of energy consumption in the productions (leaks compressed air,
power consumption equipment, data acquisition to enable the evaluation of the
current state (power measurements, pick up voltages, etc.). Relate the power
consumption to the process steps (e.g. power-time graphs);
3) Set up a value stream method based on ‘Energy intensity’. This is the
production process-related energy consumption for one product;
4) Perform analysis and define action steps for the most energy intensive process
steps. The two fundamental questions to find opportunities are:
a. Is this energy end use needed? (Does this energy really bring customer
value?);
b. Is there a way to deliver this end use more efficiently in supporting
process? (What alternatives exist to provide the needed customer
value?).
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Figure 14: Energy Value Stream Analysis is similar representation as classic VSM
visualisation (Fraunhofer, 2011)
Figure 15. Production of a front bumper made of 5 parts in 4 production steps –
calculation of energy intensity demonstrates effect of product related approach
(Fraunhofer, 2011)
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Figure 16. Example Value Stream Map shows a value stream map from a value and energy stream (EPA, 2011)
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Applicability
The lean principles can be implemented in companies of all level of maturity. These
principles can easily be translated into effective actions applicable for quick-wins in a
company (“low hanging fruit”) as well as more complex opportunities.
Economics
Lean manufacturing is proven and widely used in many companies and sectors. It proved
to be effective in reducing waste (7 types) and therefore, in more efficiently expenditure
of resources, e.g. lower energy, materials and operational costs.
Driving force for implementation
The main driving force for implementation is a combination of productivity increase with
a reduction of energy and material use.
Reference organizations
Toyota Motor Manufacturing (UK) Ltd. http://www.toyotauk.com introduced the
principles of lean manufacturing.
Daikin Europe N.V. http://www.daikin.eu, producer of heat pumps uses these principles
the reduce the energy use.
Volvo Trucks Belgium. http://www.volvotrucks.com
Reference literature Cardiff University, 2015, The Five Principles of Lean Thinking. Lean University, available
online at:
http://www.cardiff.ac.uk/lean/principles/#top, last accessed on 29th September 2015.
EPA, 2011, Lean, energy & climate tool. Report, 64p, available online at:
http://www.epa.gov/lean/environment/toolkits/energy/resources/lean-energy-climate-
toolkit.pdf, last accessed on 29th September 2015.
Fraunhofer, 2011, Increasing Energy Efficiency Using Energy Value Stream Mapping.
National Energy Efficiency Conference and EENP Awards Ceremony, Singapore, 2011.
Gonce and Somers, 2010. Lean for green manufacturing. Climate Change Special
Initiative, Energy Efficiency.
Keskin, C., Asan, U., Kayakutlu, G., 2012. Value stream maps for industrial energy
efficiency. Technology Management for Emerging Technologies (PICMET), 2012
Proceedings of PICMET '12.
Lean Enterprise Institute, 2015. Principles of Lean, available online at:
http://www.lean.org, last accessed on 29th September 2015.
Lean Manufacturing Tools, 2015, The Seven Wastes, available online at:
http://leanmanufacturingtools.org/77/the-seven-wastes-7-mudas/, last accessed on 11th
September 2015.
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Mascitelli, R., 2011, Mastering Lean Product Development: A Practical, Event-Driven
Process for Maximizing Speed, Profits, and Quality. February 15, 2011.
Miller, 2009. Green Manufacturing Tour of Toyota Tsutsumi. Panta Rei, available online
at:
http://www.gembapantarei.com, last accessed on 29th September 2015.
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2.2.2. Measures for stock reduction - while keeping customer demand
flexibility
Description
Companies in the Fabricated Metal Products sector often have an extensive stock of
materials and goods in order to cope with flexible customer demand. The stock contains
raw materials, work in progress (WIP), purchased parts and components, semi-finished
product, finished products, spare parts, etc. All these materials and goods requires
space, not only in the storage area, but also on the shop floor.
Quick Response Manufacturing (QRM) is a recent, new production approach which
drastically reduces the lead time and results in a lower stock. If products can be made in
a few days instead of a few weeks, then, at a certain moment, less materials need to be
stored in the company. QRM will reduce the stock directly, proportional to the lead time
(Little’s Law).
Shorter lead times improve quality, reduce cost and eliminate non-value-added activities
within the company, while simultaneously increasing the company’s competitiveness and
market share by serving customers better and faster.
QRM applies cellular production layouts (Figure 18) that typically require less floor space
for equal levels of production compared to functional layouts (Figure 17 and Figure 18).
The reduction in required floor space will also lead to a reduction of energy use for
heating, cooling and lighting. It can also lead to a reduction of consumption of resources
and generation of waste, e.g., fluorescent bulbs and cleaning supplies. In particular,
reducing the spatial footprint of production, the need to construct additional production
facilities, as well as the associated environmental impacts resulting from construction
material use, land use, and construction wastes, can be reduced.
QRM requires four fundamental structural changes to transform a company organized
around a cost-based management strategies to a time-based focus:
- Functional to Cellular: Functional departments must be replaced by QRM. QRM
cells become the main organizational unit. QRM cells are more flexible and holistic
in their implementation compared to other cell concepts, and can be applied
outside the shop floor;
- Top-down Control to Team Ownership: Top-down control of processes by
managers and supervisors in departments needs to be transformed to a decision-
making structure in which QRM cells manage themselves and have ownership of
the entire process within the cell;
- Specialized Workers to a Cross-trained Workforce: Workers need to be trained to
perform multiple tasks.
Efficiency/Utilization Goals to Lead Time Reduction: To support this new structure,
companies must replace cost-based goals of efficiency and utilization with the
overarching goal of lead time reduction.
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Figure 17. Scheme of a traditional organization of the shop floor (Teim, 2010)
Figure 18. Organization of the shop floor: before: traditional functional layout; after:
cellular layout (Teim, 2010)
The main building block of the QRM organization is the QRM cell. Extending the concept
of cellular manufacturing, QRM cells are designed around a Focused Target Market
Segment (FTMS) – a segment of the market in which shorter product lead times provide
the company with maximum benefits. Resources in a cell are dedicated (only to be used
for jobs in the cell), collocated (located in close proximity to each other) and
multifunctional (cover different functions). QRM cells complete a sequence of operations
ensuring that jobs leave the cell completed and do not need to return.
The work organization in QRM cells is based on team ownership. Provided with a job and
a completion deadline, teams can decide independently on how to complete the job. To
ensure quick response to high-variety demand, workers in QRM cells need to go through
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cross training. Creating spare capacity and defining optimal batch size are key elements
of this strategy.
Many cost-based organizations aim for machines and labour to be utilized at close to
100% of capacity. QRM criticizes this approach as counterproductive to lead time
reduction based on queuing theory, which shows that high utilization increases waiting
times for products and increasing inventory. In order to be able to handle high variability
in demand and products, QRM advises companies to operate at 80% capacity on critical
resources.
Common efficiency measures encourage production of parts in large batch sizes. From
the QRM perspective, large batch sizes lead to long waiting times, high WIP and
inventory, and ultimately long lead times. Long lead times in turn result in multiple
forms of waste and increased cost as described above. Thus, QRM encourages enterprise
to strive towards batch sizes that minimize lead times.
This approach requires involvement of the company executive management since it
requires an integrated approach over different company departments like sales,
materials management (supply chain), production organization, product design etc.
Product design, sales, operations and planning that are driven by lead time (time driven
production) create supporting auto-replenishment systems, cellular manufacturing
allowing fast reaction in ramping up and ramping down and in implementation of product
improvements.
Based on information of the Centre for Quick Response Manufacturing (2015) and QRM
Centre Europe (2015).
Achieved environmental benefits
Reducing defects due to faster detection has several environmental benefits:
- fewer defects decreases the number of products that must be scrapped;
- fewer defects also means that the raw materials, energy, and resulting waste
associated with the scrap are eliminated;
- fewer defects decreases the amount of energy, raw material, and wastes that are
used or generated to fix defective products that can be re-worked.
Shifting to rightsized equipment means that production equipment is sized to work best
for the specific product mix being produced, as opposed to the equipment that would
meet the largest possible projected production volume. Rightsized equipment is typically
less material and energy-intensive (per unit of production) than conventional, large-scale
equipment.
Less floor space for equal levels of production can reduce energy use for heating, air
conditioning and lighting if additional production can be realized within the same building
(European business, 2015). In other words more output is generated out of the same
resources (building and infrastructure) and with less energy, which reduces the
environmental impact
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Appropriate environmental indicators
Since stock is directly proportional with lead time (Little’s Law), the lead time can be
used as good indicator.
Additional indicators are:
- kg WIP per product range or Focused Target Market Segment (FTMS);
- kg products not meeting the quality requirements (none conforming products) per
amount of product produced;
- m² floor space for storage.
Indicators expressing the overall energy efficiency, e.g. energy consumption per product
produced (kWh per product range or FTMS).
Cross-media effects
Switching to cellular manufacturing systems, as a tool for stock reduction, can require
investment in new equipment, and potentially the need to scrap the older (or refurbish
and sell second hand), large-scale equipment geared more to batch-and-queue
operations. This can initially produce scrap for recycling and/or waste.
Rightsizing and dispersing environmentally-sensitive production processes throughout a
plant can disrupt conventional pollution control systems. For example, shifts to cellular
production is often accompanied by a shift to disperse, point-of-use chemical and waste
management, which requires an adjustment in chemical and waste management
practices. Similarly, shifts to multiple, right-sized painting and coating, parts washing, or
chemical milling operations can alter air emissions control approaches, needs, and
requirements. If environmental requirements are not addressed adequately during the
conversion to cellular layouts and rightsized equipment, the organization can impact the
environment adversely and/or fail to comply with applicable regulatory requirements.
Operational data
QRM theory recommends four common steps when implementing QRM:
QRM implementation requires company personnel to embrace the strategy’s time-based
principles. In a first step, a team of management and employees trained in QRM
principles should compile a list of time wastes, creating awareness for the negative
impact of long lead times on operations.
A cross-functional team starts studying the project, including a detailed analysis of the
critical path, product volumes, strategic needs and other factors. This analysis leads to
the definition of the Focused Target Market Segment (FTMS) for the QRM project. Using
QRM principles, the planning team designs a QRM cell for the FTMS.
An implementation team consisting of the people in the new cell and members of the
planning team can start training activities, cross-training of operators and – if needed –
relocation of equipment to launch the cell. After cell launching, the implementation team
continues support for the new cell and measures the critical path to monitor lead time
changes.
Several cases published on QRM results illustrate improvements like (Centre for QRM,
2012):
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- Lower stock (up to 60% reduction and up to 70% lower stock holding cost) and
fewer late deliveries;
- Increased stock turns (up to 40%);
- Obsolescence reduction (over 30%).
Panimpex (BE) is a SME in the Fabricated Metal Products sector with main process
activities: punching, bending, soldering, assembling. Panimpex reconsidered its
production processes in order to reduce the lead times and inventory. Table 16 below
gives an overview of the situation before and after the implementation of the stock
reduction and QRM measures (Sirris, 2014):
Table 16. Panimpex results of QRM implementation (Sirris, 2014)
Before After
Large change over time Small effective change over times
Batch size: 50 Batch size: max. 10
Lay out: scattered work stations Lay out: U- shaped cellular shape
Thru put time: 4 days per product 2 – 4 hours
Inventory: large inventory and large WIP
quantities
Small inventory parts (almost no WIP)
Provan (BE) is a metal working company. Its main activities are sheet metal and steel
pipe laser cutting, bending, forming, welding and assembling for a set of original
equipment manufacturers (OEM) customers. Without QRM in place, Provan would need
260 additional stock locations due to a customer request for two new production sets.
This would require the use of an additional warehouse building. Due to QRM approach
below results are achieved:
- Lead time reduction from 4 weeks to 3 days;
- Improved quality;
- Reduction of 600 m² storage space;
- Almost 50% lower energy cost per added value. With 50% less energy more
revenue is created.
Figure 19. Evolution of the energy use (kWh) per added value after implementing a QRM
at Provan (Sirris, Provan, 2015)
Applicability
Companies making products in low or varying volumes (not only in the Fabricated Metal
Products sector) have used QRM as an alternative or to complement other strategies
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such as Extend the lean principles with measures for energy and material consumption
(§2.2.1).
The QRM principles can be applied in large scale as well as small scale organizations. The
cellular approach and the single (small lot size) batches can be implemented in most
Fabricated Metal Product manufacturing companies.
The supporting replenishment and control systems can be adjusted to the company’s
needs. Multiple supporting companies exist to guide companies towards QRM–
implementation.
Economics
Unused or dead stock generates direct and indirect costs, including:
- Opportunity Cost: Dead inventory is money that is just sitting on shelves without
producing any profit. It is an opportunity cost of investing the money in another
business.
- Direct losses: Obsolete parts must be "scrapped", or sold under the price, which
means a direct loss. Selling obsolete steel parts as scrap for example does not
offset the cost of the raw materials and the indirect cost of manufacturing the
parts.
- Hidden costs. Dead inventory incurs in costs such as insurance, rental space for
storage, taxes, and time lost performing inventory recounts (Autologica, 2012).
Driving force for implementation
The main driving force for implementation is becoming (more) flexible and reactive to
customers demand. This lead to:
- Reduction of total order to delivery time;
- Reduction of finished goods stock;
- Ability to respond to unexpected changes in demand without a degradation of
service;
- Development of a cross-trained workforce for flexibility;
- Reduction last shot (last good piece) to first shot time (first good piece).
Reference organizations
Provan (BE). Tailor made metal solutions, incl. Quick Response Manufacturing.
http://www.provan.be
Bosch Hinges (NL) BOSCH Hinges designs and manufactures high quality metal bespoke
hinges for industrial applications, specialized in customized precision work.
http://www.boschhinges.com
Nederman Manufacturing (PO). The Nederman Group is a world leading supplier and
developer of products and solutions within the environmental technology sector.
http://www.nederman.com
Legrand (NL). Specialist in electrical and digital building infrastructures, QRM.
http://www.legrand.be
Reference literature
Autologica, 2012, 10 Important Indicators Managers Should Monitor - Part 3. Autologica,
Dealer Management Systems, available online at:
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http://www.autologica.com/index.php?q=es/nota/4/81
Baudin, M., 2015, When to Use Statistics, One-Piece Flow, or Mistake-Proofing to
Improve Quality. Institute of Industrial Engineers. available online at:
https://www.iienet2.org/Details.aspx?id=6006
Centre for QRM, 2015. available online at:
http://qrm.engr.wisc.edu/, last accessed on 14 September 2015.
Centre for QRM, 2012, Results and Testimonials. Centre for Quick Response
Manufacturing, University of Wisconsin-Madison, available online at:
http://qrm.engr.wisc.edu/index.php/results, last accessed on 14th September 2015.
European business, 2015, Quick response manufacturing in metal subcontracting,
available online at:
http://www.european-business.com/provan_bvba/portrait/, last accessed on 14th
September 2015.
EPA, 2015, Cellular Manufacturing, Lean thinking and methods. United States
Environmental Protection Agency, available online at:
available online at: http://www.epa.gov/lean/environment/methods/cellular.htm, last
accessed on 14th September 2015.
Pay, 2010, Consider This -- Avoiding Obsolete Inventory. IndustryWeek, Advancing the
Business of Manufacturing, available online at:
http://www.industryweek.com/articles/consider_this__avoiding_obsolete_inventory_218
62.aspx, last accessed on 14th September 2015.
Selko, 2011, Moving Beyond Lean: Quick Response Manufacturing. IndustryWeek,
Advancing the Business of Manufacturing, available online at:
http://www.industryweek.com/companies-amp-executives/moving-beyond-lean-quick-
response-manufacturing, last accessed on 14th September 2015.
Sirris, 2014, Driving Industry by technology, Panimpex, available online at:
http://blog.sirris.be/nl/blog/panimpex-verbetert-productieaansturing-en-verkort-
doorlooptijd, last accessed on 14th September 2015.
Sirris, 2015, Provan voert drastische doorlooptijdverkorting door in de productie,
available online at:
http://sirris.be/nl/success-story/provan-voert-drastische-doorlooptijdverkorting-door-de-
productie, last accessed on 14th September 2015.
Teim, 2010, product flow, available online at:
http://www.teiminc.com/product_flow.htm, last accessed on 14th September 2015.
QRM Centre Europe, 2015, available online at:
http://www.qrm-centrum.nl/, last accessed on 14th September 2015.
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2.2.3. Cross-sectoral and value chain collaboration (by communication and
integration)
Description
In order to optimize processes and use of energy and resources at a more systemic
level, collaboration of companies, cross-sectoral and throughout the value chain, is
required. This is also the case for companies in the Fabricated Metal Products sector.
Knowledge of the entire life cycle, value chain and networks relevant for the
manufacturing processes are of utmost importance for further optimization of the
processes.
This generic idea can be applied for the Fabricated Metal Products sector. Two major
areas of collaboration are energy use and use of resources. In case of excesses of
electricity or heat, an energy based collaboration can be set up. A waste stream
generated in one company can be valuable resource for another company, and thus lead
to a resource based collaboration.
Setting up cross sectoral collaborations can lead to industrial symbiosis. An industrial
symbiosis is a local collaboration where public and private enterprises buy and sell
residual products, resulting in mutual economic and environmental benefits. This means
that two or more companies become interdependent of each other for their resource
streams or energy streams. The largest industrial symbiosis network in Europe is
situated in Kalundborg (Denmark). The Danish industrial symbiosis network consist of
more than 15 companies from different sectors. However no companies from the
Fabricated Metal Products sector are involved in the Kalundborg network. There is
potential for cross sectoral collaboration, but on a smaller scale.
Companies in the sector need support to set up cross sectoral collaborations. Facilitating
and targeted networking initiatives, focusing on matchmaking between companies (in
and outside of the sector) help to overcome the barriers and improve the required
knowledge and contacts. Matchmaking can be situated on several levels. Examples from
the Fabricated Metal Products sector are linked to:
- Reuse of waste streams, including waste from metal product fabrication, e.g.
cake, scrap, coating powder and solvents.
- closing the loop of valuable materials, e.g. special metal alloys.
- Linking materials’ demand or equipment need with waste streams or standby,
back-up or redundant equipment in other companies.
To match supply and demand additional research and pilot projects are needed.
However, anyone who has tried to catalyse business change, knows that this can and will
never happen overnight. New practices are often taken on as pilot projects, prototypes
or incremental tweaks, testing the water for a wider rollout if the numbers stack up and
others are on board (Ellen Macarthur Foundation, 2015). This cross-sectoral and value
chain collaboration is beneficial for both large and small companies. Identifying the
appropriate collective platforms for matchmaking are a good starting point.
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Figure 20. Representation of Industrial Ecology processes (GPEM, 2015)
To get started, the following steps can be used as guide:
- Identify the opportunity by mapping the energy or resource streams and their
value/costs;
- Map all stakeholders in the process;
- Search for matchmaking companies;
- Identify the knowledge gaps and support needs to further elaborate the
opportunity;
- Define and set up (small) scale experiments;
- Gradually extend the number of involved partners (stakeholders) to build up a
more robust network.
Achieved environmental benefits
Cross-sectoral and value chain collaboration between companies will lead to a more
optimal use of resources (e.g. materials, equipment, capacity, etc.) and energy and will
lead to a more rational waste management. Due to this optimization significant reduction
of CO2 emissions can be achieved throughout the entire value chain. The collaboration
initiatives, often starting from small scale experiments, enable open innovations and
lower the barrier for future collaboration initiatives, which will eventually lead to a
reduced environmental impact. Furthermore, due to the increased knowledge sharing via
various platforms, knowledge building will be more efficiently.
Appropriate environmental indicators
Appropriate environmental indicators are:
- Participation in industrial symbiosis networks and exchange of material/energy
etc. - Y/N;
- The amount of waste and sidestreams valorised outside the companies;
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- Use of by-products or other energy sources from other industries within the
industrial symbiosis network in various processes of Fabricated Metal Products
industries:
o scrap or other by-products – Y/N
o steam – Y/N
o renewable energy – Y/N
The CO2 emissions in and outside the company, gives also a good indication, but to
measure this, larger studies (e.g. Life Cycle Analysis) are needed to define the overall
impact. Performing such a study and comparing the impact before and after (full)
implementation provides better insights. In doing so, additional information on the main
sources of impact is gathered whereas it is important to define precisely the borders of
the carried out LCA study. To further control the process and make progress, focus on
the life cycle phase with most impact might be a good indicator e.g. the functional unit
of the carried out LCA study might be a meaningful and sound indicator. The Agfa case
(see below) illustrates this. Since the production of aluminium is responsible for 80% of
Agfa’s climate change impact, the associated CO2-emission in this life cycle phase is a
good metric.
Cross-media effects
The overall environmental benefit might be compromised if only the economic interests
are envisaged at the starting point (Marinos-Kouris and Mourtsiadis, 2013).
The environmental impact of cross sectoral collaborations is determined by reviewing the
full material flows. This takes into account the benefits achieved, as well as the
additional impact created. This to put the impact into perspective.
As an example, in the Agfa case the eco-impact associated to the use of raw materials is
so high that the eco-impact of the recycling operations and reverse logistics are not
significant.
The full life cycle needs to be examined to assure the overall environmental impact is
reduced, and there is no shift from one life cycle phase to another.
Operational data
Some of the matchmaking initiatives are listed below.
Case study: Brainform (UK) – garment hanger re-use
Platforms, like Brainform, are looking for a maximum impact, they are not limited to the
Fabricated Metal Products sector only: Brainform (UK), the global leader in garment
hanger re-use, are seeing the far-reaching benefits of a circular business model by
closing the materials loops of their products. The company belongs to both the
Fabricated Metal Products and plastics processing sector (steel parts formed from wire &
plate which are integrated in plastics parts). Their closed loop process allows the
company and its clients - major retailers and garment suppliers - to work together. By
re-using their hangers, retailers can reduce costs and improve efficiencies by extending
the lifespan of a garment hanger beyond a single use.
This loop works as follows: after being contracted by a new partner, Brainform develops
a new garment hanger solution, which starts with supplying virgin product into the
market. Manufacturers buy these hangers and deploy them before shipping their
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products. The garments are distributed and during purchase, the retailer collects the
hangers, sending them back to distribution centres. In a next step the hangers go back
to one of three main re-use centres where they are sorted, repackaged and distributed
back to garment-producing regions. Hangers that cannot be re-used are shredded and
used to make new products (Figure 21).
Figure 21. The Brainform re-use program (Brainform, 2015)
Even the best re-use systems require top-ups to keep the model working. Now,
Brainform uses relationships with injection moulding production partners around the
globe to manufacture the virgin hangers, rather than owning the factories and
equipment themselves.
This shift has offered clear benefits for the company. Firstly, moving to re-use meant
that Brainform became largely independent from fluctuating oil prices (significant for the
plastics parts), enabling them to remain competitive and improving client relationships.
The company collects and shreds hangers for a number of clients, including those who
are not part of the re-use program. The re-use model has also created jobs. This model
is also less reactive to the fashion seasons, with the workforce remaining stable and
consistent throughout the year, rather than creating unhelpful peaks and troughs.
Brainform’s re-use infrastructure also helps retail partners to save money on their waste
removal as a value added service.
By moving from take-make-dispose to a closed loop of the materials, Brainform is
demonstrating the multiple benefits that circular business models can bring: materials
cost savings, greater resilience from price volatility, closer client relationships and new
jobs (Brainform, 2015).
Case study: VOM (BE) - reuse of powder coating
A study by the VOM (Belgium association for surface finishing techniques, Spooren,
2012) gives different possibilities for reuse and recycling of waste from the powder
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coating process. For reuse as powder coating, the waste streams has to be collected
separately by colour and may not contain impurities (like dust). The reuse companies
are chemical firms who produce powder coatings (e.g. Fina Research S.A. and E.I. Du
Pont de Nemours & Co).
Another option is to use the waste from the powder coating process to produce other,
new materials (composites). This option is useful for powder coatings containing
materials like urethane, epoxy, acryl or polyester. There is no necessity to keep colours
separately and small impurities (like grind, stones) are acceptable. Steelcase and GMI
Composites have set up a collaboration to recycle waste from the powder coating
process.
Case study: Steelcase (US) – reuse of waste from powder coatings
Steelcase, an office furniture manufacturer in the Fabricated Metal Products sector,
provides ergonomic seating through leasing. The steel parts of the seats are powder
coated in their manufacturing plant. By creating new relationships the overspray and
excess coating powder of Steelcase is now used as a resource for GMI Composites. GMI
Composites uses the powder as a matrix material to manufacture light weight manhole
systems using a sheet moulding compound process. The process is patented (US
20080153932 A1, 2007).
Case: DENSO Manufacturing (UK) - Matchmaking initiative NISP (National Industrial
Symbiosis Programme - NISP, 2012), objective: support DENSO Manufacturing in finding
more sustainable waste treatment.
DENSO Manufacturing (UK) is manufacturing air-conditioning units for the automotive
industry. The company had already established a sustainable disposal route for waste
filter cake generated as part of its process, but was keen to identify a more sustainable
option that required less transportation and offered greater environmental benefits.
DENSO Manufacturing UK attended a number of NISP ‘Resource Matching’ workshops.
They further benefitted though on-site visits and practitioner support. The NISP
practitioners looked at all manufacturing processes in order to identify ways in which to
further eradicate waste at source and effective recovery, reprocessing and reuse options
when waste was unavoidable. The filter cake produced in the effluent treatment plant at
DENSO has 70% moisture content. NISP recommended implementing an on-site solution
using waste heat from the company’s manufacturing systems to dry the cake (Figure
22), making it suitable for use in an alternative processes. The new system has reduced
transportation and the material is now used in three additional processes, significantly
impacting on the company’s carbon footprint. Once dried, the product is sent to another
company, where it is crushed for use as an active agent in the absorption of oil and
solvent. This agent is then employed as a fuel source, before the residual:
- Reduction of 18 tonnes of waste filter cake by drying it and reducing moisture
content of the cake;
- Cost saving of £5,000 (€ 6,600) as a result of waste minimization (reduced
quantity of cake to be disposed of) and transport;
- Road transport requirements were reduced by 200 miles per year (CO2
reduction).
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Figure 22: DENSO filtercake (NISP, 2012)
Case study: Band Saw manufacturer (UK) & CTS Environmental Services Ltd (NISP) –
recycling metals form waste
Manufacturing band saws require grinding operations which generates waste. This waste
consists of grindings, mineral oil (coolant) in the form of a cake (Figure 23). Initial this
grinding cake was treated as hazardous waste. The concentration hazardous component
was below the hazardous waste threshold level. A recycling facility was found to recycle
the metals in the cake, resulting in:
- A reduction of 80 tonnes/year of hazardous waste;
- A CO2-reduction of 153 tonnes/ year.;
- 80 tonnes/year of materials recycled.
Figure 23: Oily grinding cake (NISP, 2009)
Case study: AGFA (BE, DE): Closed loop of aluminium offset printing plates
One of AGFA’s activities is the manufacturing of offset printing plates. AGFA modifies the
surface of AA 1000 alloy aluminium (+99.3% pure Al) to produce products with specific
quality for optimal printing performance. The offset printing plates are perceived as
consumables for the suppliers and are in general valorised by the printers as high quality
(pure) aluminium. Due to the pressure and volatility of the prices ,Agfa decided to try to
close the material loop. Their objectives were: avoid ‘downcycling’ (Figure 24) of used
plates by developing a recycling process for lithographic aluminium, no impact on
product quality, reduce the carbon footprint, asses the environmental impact of the
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reverse logistics (for Agfa and for the customer) and no increase of the product cost.
Phase 1 only involved Agfa’s production plants, while phase 2 involved their European
customers (Figure 25).
Figure 24: Agfa’s old scrap flow (Pellegroms, 2015)
Figure 25: Agfa’s new scrap flow (Pellegroms, 2015)
The product quality was controlled, while they gradually increased the recycled content
from 10% up to 100%. Validation by own labs, as well as blind tests by selected
customers assured the quality was maintained. In phase 2, a new business model in
which printing plates are leased required new marketing and sales targets and increased
the need for additional partners specialised in the reverse logistics and recycling.
Since aluminium production is responsible for 80% of the climate change impact, the
achieved environmental benefits in this case is significant. The CO2-footprint has
decreased from 11.1 kg/m² to 3.1kg/m² (Pellegroms, 2015; Verschave, 2012).
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Figure 26: Carbon footprint Agfa (Verschave, 2012)
Case study: Volvo Cars (BE) - Use of waste heat from neighbouring company
StoraEnzo, a producer of paper mill has a CHP (Cogeneration or combined heat and
power) installation on biomass. StoraEnzo uses the electricity itself. The heated water is
transported to the neighbouring company, Volvo Cars.
As a direct result, Volvo Car has reduced, its use of fossil fuels for heating purposes. The
CO2-emission has decreases with 15 000 tonnes per year, a net decrease of more than
40% of total CO2-emission of the plant (StoraEnzo, 2014).
Case study: Steel Service Centre (BE) – Collaboration with food producer
The SME Steel Service Centre (BE) is a weld shop that has invested in photovoltaic cells
to provide electricity for their manufacturing processes. What is different from other PV
installations is that they are not connected to the grid to supply the surplus energy.
Surplus energy arises in the weekend, as no welding operations take place at that
moment. The company provides its surplus energy to its neighbouring company Quality
Meat Products, a company that has a large and almost invariable energy demand for
cooling of their meat products.
Applicability
Searching for cross-sectoral and value chain collaboration has an inherent risk. Not all
projects result in economic success stories. Business change can and will never happen
overnight. New practices are often taken on as pilot projects, prototypes or incremental
tweaks, testing the water for a wider rollout if the numbers stack up and others are on
board. (Ellen Macarthur Foundation, 2015). Such an iterative approach and search for
different partners, processes etc. always result in increased knowledge and extended
network partners.
Critical factors for cross-sectoral and value chain collaboration are (Ellen Macarthur
Foundation, 2015):
- The willingness to explore paths for collaboration and to take risk.
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However, existing funding schemes in several EU countries contribute to
overcome this barrier;
- Logistics and approximation of companies.
They are after all an important cost factor;
- Clear agreements about intellectual property (IP) between all involved actors
(providing company, receiving company and intermediate actors);
Typical questions to be answered are: Who owns the technology? And who can
further commercialize this technology?
- Clear and common targets to ensure a win-win situation for all partners;
- Flexibility to change in partner selection, based on gathered insights and
knowledge.
Economics
The economics of cross-sectoral and value chain collaboration, highly depend on the
business case. The case of DENSO Manufacturing (UK) supported by the matchmaking
initiative NISP (see Operational data) resulted for example in a cost saving of £5,000
(€ 6,600) as a result of waste minimization (reduced quantity of cake to be disposed of)
and transport (NISP, 2012).
AGFA was able to reduce the volatility of price of their aluminium material by closing the
material loop.
For the reuse of waste from powder coatings the economic viability depends on quality of
the waste and the type of collaboration. For high value reuse options (like production of
new powder coatings), the Fabricated Metal Products companies will not pay anything for
removing their waste, this is in contrast to traditional collection, for which they have to
pay up to 450 €/ton (without transport cost) (Spooren, 2012).
Driving force for implementation
The main driving forces for cross-sectoral and value chain collaboration are an increased
efficiency of resource use leading to an overall cost reduction, an increased
environmental performance and better business reputation. The collaboration initiatives
also result in significant knowledge acquisition and increased resilience by the extending
partnering network.
Reference organizations
NISP, the National Industrial Symbiosis Programme, has been in place in the UK since
2003, and is the world's first National Industrial Symbiosis Programme. NISP provides a
platform to inspire businesses to implement resource optimization and efficiency
practices, keeping materials and other resources in productive use for longer through
industrial symbiosis. (http://www.nispnetwork.com/). In Belgium there is a comparable
programme, called SmartSymbiose (http://www.smartsymbiose.be).
Harvestmap (Oogstkaart in Dutch) is a new online marketplace for redundant and
second hand materials. Harvestmap/Oogstkaart allows companies or individuals to make
an inventory of their supply of materials, components or even buildings to Superuse (see
below). All materials, ranging from small quantities to continuous flows of (industrial)
leftovers are presented. Registration to Superuse.org gives access to Oogstkaart too.
Participation allows you to share supply, provide tips to the community and find available
resources in the neighbourhood or the surroundings of a project. Oogstkaart is currently
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(2015) in Beta version as they are continuing to improve the platform, making sharing
resources become even more simple. Registration is required.
Superuse.org is an online community of designers, architects and everybody else who is
interested in inventive ways of reuse of materials, elements and components. The site
allows you to post items at various scales within the reuse-topic. All examples of small
commodities, furniture, interiors, buildings and reuse on urban scale are welcomed. Next
to exhibiting applications, we promote the development of knowledge on the subject by
starting up discussions, adding historical background and allowing user comments.
FLOOW2 is the business-to-business sharing marketplace where companies and
institutions can share equipment, services, and the skills and knowledge of personnel.
Companies can provide or request specific equipment, or service. The transactions can
be based on borrowing, renting purchasing agreements. It allows companies to lower the
risk while experimenting, reduce costs or generate extra income and connect with other
companies currently outside their horizon. The benefits are: Stimulation of servitisation
and discouragement of ownership by sharing equipment and optimal resource use (less
equipment needed to deliver the same performance).
http://www.floow2.com/sharing-marketplace.html.
ActClean Matchmaking shows a database of cross sectoral good practices and strives to
become the matchmaking platform for SME’s.
http://www.act-clean.eu/index.php/Act-Clean-Matchmaking;182/1
Dokota (BE) is a company working together with Fabricated Metal Products companies
(and other) to reuse their waste from the powder coating lines.
http://www.dakotaworldwide.com/
Steelcase (US) an office furniture manufacturer in the Fabricated Metal Products sector
provides ergonomic seating through leasing. Their steel parts are powder coated in their
manufacturing plant. By creating new relationships the overspray and excess coating
powder of Steelcase is now used as a resource for GMI Composites.
http://www.steelcase.com/
Volvo cars (BE) uses heat water of a neighbouring company and reduces its direct
emission of greenhouse gasses.
http://www.volvocargent.be/
Reference literature Brainform, 2015, CSR, available online at:
http://www.braiform.com/en-gb/about-us/corporate-social-responsibility/ last accessed
1st September 2015.
Ellen Macarthur Foundation, 2015, Brainform, the global leader in garment hanger re-
use, are seeing the far-reaching benefits of a circular business model by making a
commitment to the inner loops of the technical cycle, available online at:
http://www.ellenmacarthurfoundation.org/case_studies/braiform, last accessed 1st
September 2015.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 124
GDRC, 2015, The Global Development Research Centre. Sustainability Concepts,
Industrial Ecology, available online at:
http://www.gdrc.org/sustdev/concepts/16-l-eco.html last accessed 1st September 2015.
GPEM, 2015, Research Projects in Industrial Ecology and Circular/Green Economy.
School of Geography Planning and Environmental Management, available online at:
http://www.gpem.uq.edu.au/industrial-ecology-opportunities last accessed 1st
September 2015.
Marinos-Kouris, D., Mourtsiadis, A., 2013, Environmental limits of industrial symbiosis:
The case of aluminium eco – industrial network. Fresenius Environmental Bulletin,
Volume 22, 12.2013.
NISP, 2009, National Industrial Symbiosis Programme – Case Studies. Recycling Oily
Waste Is A Piece Of Cake, available online at:
http://www2.wrap.org.uk/downloads/4864_-
_Recycling_Oily_Waste_Is_A_Piece_Of_Cake.2272da62.8890.pdf last accessed 1st
September 2015.
NISP, 2012, National Industrial Symbiosis Programme – Case Studies. DENSO has its
cakes and H-eats it!, available online at:
http://www.nispnetwork.com/media-centre/case-studies/40-denso-has-its-cake-and-h-
eats-it last accessed 1st September 2015.
Patents, Uses of waste stream from the production of powder coat, US20080153932 A1,
2007, available online at:
http://www.google.com.ar/patents/US20080153932 last accessed 1st September 2015.
Pellegroms E., 2015, Agfa Graphics NV. Presentation Vlaams materialmen programma.
available online at:
https://www.google.be/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&cad=rja&uact=8
&ved=0CCIQFjAAahUKEwjV88PL2u7HAhUGjtsKHSooAYQ&url=http%3A%2F%2Fwww.vla
amsmaterialenprogramma.be%2Fsites%2Fdefault%2Ffiles%2Fatoms%2Ffiles%2FPresen
tatie%2520Agfa.pptx&usg=AFQjCNGiXbowse7AMxOAEWwZd-OEDdUJXg&sig2=aSW-
JhcN8VuKVuzTe_okng last accessed 1st September 2015.
Restore, 2015, available online at:
http://www.restore.eu/ last accessed 1st September 2015.
Spooren J., 2012, Poederlakafval: de Belgische markt, de verwerkingsmogelijkheden en
de toekomst. Study VOM – VITO.
StoraEnzo, 2014. Stora Enso joins forces with Volvo to cut CO2 emissions.
http://www.storaenso.com/about/news/stora-enso-joins-forces-with-volvo-to-cut-co2-
emissions
Verschave P., 2012, Closed loop recycling for lithographic aluminium? Presentation IFEST
16 February 2012.
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2.2.4. Chemical leasing & Chemical management services
Description
In a circular economy, equipment and utilities (electricity, natural gas, water, etc.) are
to be used as efficiently as possible. Companies in the Fabricated Metal Products sector
are characterized by a high use of resources, especially of raw and auxiliary materials..
Efficient use of resources will lead immediately to several environmental and economic
benefits. Chemicals (solvents) for example are extensively used in the sector for various
applications, e.g. degreasing, cleaning and coating. A proven best practice for an
increased efficiency of the use of chemicals is changing from buying chemicals to buying
the functionality of the chemicals (degreasing, cleaning, coating, etc.). Chemical leasing
(ChL) and Chemical Management Services (CMS) are examples of this concept.
ChL:
Instead of the conventional business model of buying and disposing of products, i.e.
chemicals, companies can lease these products as, after all, they are only interested in
the functionality of the chemicals. From a supplier's perspective there is a shift from the
idea of providing / selling the chemicals towards the idea of providing the functionality,
e.g. number of square meters degreasing /de-oiling. Within the concept of ChL, the
suppliers will sell square meters of cleaned surface or number of parts cleaned instead of
a certain quantity of chemicals. From a user's perspective, ChL will lead to reduced costs
and risks, while maintaining the quality and reliability. An important aspect of ChL is that
both suppliers and users become partners with common incentives or targets, which is
different from the traditional business model. In the traditional business model, the
supplier is interested in selling as much chemicals as possible, while the users want to
reduce the amount of chemicals used (Figure 27). Another important difference with the
conventional business model is that ChL makes the suppliers in charge of the (re-
)treatment of the used chemicals. In fact, in the conventional business model the users
of the products are responsible for disposing of the chemicals, while in the concept of
ChL, the suppliers take care of that. Within the concept of ChL, suppliers and customers
have the same benefits, i.e. both are triggered by a reduction of energy use, resource
efficiency, etc. Companies offering ChL often provide also their knowledge to select
chemicals and technologies (to use these chemicals) with the highest performance (for
the specific case) and the lowest environmental impact. E.g. chemicals with the
appropriate characteristics for the materials treated, reduce the energy consumption of
the processes where chemicals are used. The involvement of the suppliers differ from
case to case.
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Figure 27. ChL business model compared to the conventional business model (Dow
Safechem 2015)
Apart from the aligned interests of suppliers and consumers, ChL will also lead to several
other benefits. Invoicing for example will be based on a product performance parameter
like parts cleaned or life-time of the solvent29 instead of the quantity of solvent used.
Furthermore, ChL will trigger the optimization of cleaning processes by steering the
process and lead to an enhanced pooling of know-how within a service alliance
throughout the entire value chain.
CMS
There is no exact definition of CMS. In a CMS business model the supplier of a chemical
offers a series of chemical related services, like pollution monitoring, maintaining MSDS,
personnel training, laboratory works, etc. The range of chemical management services
varies considerably.
Chemical Management Services are similar to ChL, but do typically not include the
equipment (capital goods) to perform the cleaning operations. CMS is often a good start
for small scale experiments with chemical as a service.
A good way to start with CMS is: (based on Chemical strategies partnerships, 2015)
- Inventorise processes using chemicals: high level inventory, chemical usage and
related costs;
- Look for partners (ChL or CMS) based on processes, type of chemicals, amount of
chemicals and related cost;
- Set the baseline for chemical cost: map of life cycle stages & organizational
functions, cost analysis (over all life cycle phases of the chemicals);
- Develop an action plan: prioritisation of products and processes, case studies
(scenario analysis), identification of performance measures;
29
The Fabricated Metal Products company will sell a “service” e.g. availability of a certain solvent X with
quality Y. The supplier of the solvent will choose his own strategy to fulfil these requirements (e.g. changing
the solvents when needed, or provide a solvent regeneration unit, etc.).
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- Further engage partnerships: stakeholders analysis, service providers, business
case, definition of roles and responsibilities.
Difference between ChL and CMS
There are only few differences between the two business models. Payments can either
consist of a fixed fee or be quantified (like in the ChL model) in functional units.
The main difference is that the services offered in a ChL model focus on the optimization
of the application process of a certain chemical, while CMS may encompass many other
services. These services often concern the full pallet of chemicals used in a company that
may not all be provided by the company offering the CMS. In the context of ChL, on the
contrary, the company offering the services also supplies the chemical(s) it offers the
services for. (Chemical Leasing, 2015)
Achieved environmental benefits
The most important benefit of ChL, compared to the traditional business model, is that it
lead to a more efficient use, and therefore a reduction in the amount, of chemicals used
and disposed of. Other important benefits of ChL are:
- Knowledge enrichment, needed to optimize the processes in order to reduce the
consumption of chemicals;
- Reduction of the quantity and frequency of deliveries and associated packaging
waste (pallets, shrink wrap, etc.);
- Avoiding of redundant chemicals;
- Stimulation of substitution of hazardous chemicals;
- Reduction of customer’s chemical waste (up to 10%, see Figure 28);
- Avoidance of underutilized chemicals, especially among small to mid-sized
companies;
- Reduction of chemicals used (10 to 30% -see Figure 28);
- Reduction of energy used (due to less cleaning cycles, storage of chemicals, up to
10% ; -see Figure 28);
- Reduction of the water use (due to less cleaning cycles, up to 25% -see Figure
28).
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Figure 28. Case study illustrating the potential of ChL (The Guardian, 2014, based on
data from Ecolab, Stockmeier, Johnson).
Appropriate environmental indicators
Appropriate environmental indicators for ChL are:
- Use of solvents or chemicals, typically expressed as amount of chemicals used
per part cleaned or amount of chemicals used per m² cleaned;
- Emission of VOC, typically expressed as amount of VOC per part cleaned and
related health and safety risks;
- Health and safety risk can be evaluated by performing a risk assessment before
and after implementation of ChL, and a comparison of initial and residual risks
(Yes/No).
- Energy use for processes related to the use of solvents or chemicals, typically
expressed as number of parts cleaned per kW.
Cross-media effects
There are no cross-media effects due to the implementation of ChL. The responsibility
for disposing of and (re-)treating used chemicals shifts from the perspective of the users
to the suppliers.
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Operational data
In the Aircelle Ltd (Burnley, UK) case, ChL was implemented. The company changed its
cleaning equipment. The new equipment operates under closed, vacuum conditions.
Emissions of chemicals stay below 1 ppm. Consumption of solvents was reduced by this
new equipment. The services provided resulted in a 10% reduction of solvent
consumption. Additional, the machine utilisation went to 99%, due to a better supply of
chemicals. Compared to the initial situation the company’s annual solvent consumption
dropped by 92.7%, and a reduction of energy cost by 50% was realized. Additional
financial advantages were obtained thanks to reduced administrative costs, the supply
matching exactly the needs avoiding mitigation actions for short falling, etc. (Dow
safechem, 2014).
At BAE Systems (Samlesbury, UK) ChL and new cleaning equipment led to a solvent
reduction (trichloroethylene) from 5 ton to less than 0.5 ton per annum (i.e. a 90%
reduction) (Dow safechem, 2012).
Applicability
ChL can be implemented in companies using chemicals for various applications, e.g.
degreasing and cleaning. ChL will be mostly beneficial for companies using solvents and
chemicals with a high environmental impact.
All companies using a large amount of chemicals (primary and secondary chemicals) can
minimum apply a CMS.
Without strong support of the company’s management, it can be very difficult implement
ChL. All company levels must be involved in the implementation. A lack of knowledge
about possibilities offered by suppliers, can also pose a problem. The implementation of
ChL can further be hindered by the lack of credible, independent information on the
benefits of ChL.
Economics
ChL will lead to a more efficient use of chemicals, and therefore the total costs related to
the use of chemicals, including transport costs, will be reduced.
ChL reduces the high transport costs of buying loads of chemicals from few suppliers (on
average 65-75% of all chemicals purchased are from manufacturers/resellers who supply
1-3 line items).
ChL is nowadays widely used in the automotive, aerospace and microelectronics sector.
The environmental benefits observed here include reduced chemical use, reduced
emissions, and reduced waste generation, as well as substantial cost savings. A total
average cost reduction of 30% has been achieved in the first five years (EPA, 2012).
Driving force for implementation
Several driving forces for the implementation of ChL can be identified:
- Risk reduction (HS&E);
- Cost saving;
- Broader knowledge of cleaning processes by partnering with chemical suppliers
Reference organizations
The following companies in the Fabricated Metal Products sector have successfully
implemented ChL:
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Aircelle Ltd. (Burnley, UK): Aircelle Ltd. is the U.K. is a large manufacturer of engines
and components applied in the aerospace industry.
http://www.aircelle.com
BAE Systems (Samlesbury, UK): BAE Systems is a large provider of defence and security
products primarily for military applications.
http://www.baesystems.com
DHD-technology (DE): produces metal nets for different industries (filtration, textile
cleaning, automotive, etc.) They extend the lifecycle of their chemicals in use by use of
ChL. (Chemical leasing, 2015).
http://www.dhd-technology.de/
Chemical Leasing provides a list of companies that have implemented ChL and the
benefits they achieved. The list is available on:
http://www.chemicalleasing.com/sub/pilot.htm.
Reference literature
Chemical Leasing, 2015, What are the differences between Chemical Leasing and the
classical form of leasing? available online at:
http://www.chemicalleasing.com/sub/faq.htm#, last accessed on 7th September 2015.
Chemical Leasing, 2015, Draft Database of Chemical Leasing Projects, available online
at:
http://www.chemicalleasing.com/docs/database.pdf, last accessed on 15th September
2015.
Chemical Strategies Partnership, 2015, Implement CMS, available online at:
http://www.chemicalstrategies.org/implement.php, last accessed on 7th September
2015.
Dow Safechem, 2015, CHEMAWARE™ Sharing Knowledge - Chemical Leasing. available
online at:
http://www.dow.com/safechem/eu/en/chemaware/sustain/chemleasing.htm, last
accessed on 7th September 2015.
Dow Safechem, 2014, Environmentally compliant surface cleaning with maximum
performance, available online at:
http://www.dow.com/safechem/eu/en/pdfs/773-18601.pdf, last accessed on 7th
September 2015.
Dow Safechem, 2012, NEU-TRI™ E Trichloroethylene – The approved grade at BAE
Systems Samlesbury, available online at:
http://msdssearch.dow.com/PublishedLiteratureDOWCOM/dh_08b9/0901b803808b95b8.
pdf?filepath=safechem/pdfs/noreg/773-16901.pdf&fromPage=GetDoc.
ECOLINK. Providing Lean(er) Chemical Solutions for the Next Generation, available
online at:
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http://www.ecolink.com/which-is-better-chemical-management-or-chemical-leasing/.
Ensia, 2014, Cleaning Up With Rent-a-Chemical, available online at:
http://ensia.com/features/cleaning-up-with-rent-a-chemical/, last accessed on 7th
September 2015.
EPA, 2012. United States Environmental Protection Agency, Chemical Management
Services, available online at:
http://www.epa.gov/epawaste/hazard/wastemin/minimize/cms.htm, last accessed on 7th
September 2015.
The Guardian, 2014, Chemicals are everywhere. Can a new business model make their
use greener? The Guardian, 9 December 2014, available online at:
http://www.theguardian.com/sustainable-business/2014/dec/09/chemical-leasing-
ecolab-coke-ikea-gm-un-cleaning-environment.
Oksana M. , Pranshu S. and Z. Fadeeva , 2006. Chemical management Services in
Sweden and Europe- Lessons for the Future. Lund university. Journal of Industrial
Ecology (Vol. 10, number 1-2).
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2.2.5. Energy management
Description
The initial steps in developing an effective energy management strategy involve
assessing the drivers of an organisation's energy consumption, monitoring its energy
usage, and identifying areas for improvement. Actions will then be deployed to reduce
energy demand (through energy efficiency measures) and reduce the impact of energy
supply
Some Fabricated Metal Product manufacturing processes tends to be especially more
energy-intensive than other, however, a holistic investigation of the energy flows
throughout a facility can help achieve significant savings in energy resulting in both cost
and GHG emission improvements. This cross-cutting BEMP does not aim to develop
specific process solutions relevant to individual process (some of which are developed
later in the document) but rather to outline the range of energy efficiency solutions
which should be investigated to achieve best practice.
An energy management system (EnMS) can be based on a standardised or customised
form. Implementation according to an internationally accepted standard can give higher
credibility to the EnMS and also open up opportunities for gaining certification against
certain industry standards. The purpose is similar to that of establishing an
environmental management system (EMS), but with a clear emphasis on energy
consumption.
Energy management plans and target-setting are important to allow energy efficiency to
be incorporated into management activities. Plans should include the following aspects
(Carbon Trust, 2013):
- Establishing an energy strategy involves setting out how energy will be managed.
It should contain an action plan of tasks, which will initially involve understanding
the organisation's current position and establishing the management framework;
- Gaining active commitment from senior management: without the support of
senior managers, the effectiveness of the energy management plan is likely to be
compromised. Clear responsibilities for energy consumption must be allocated;
- Performance measurement: identifying energy savings is an ongoing process
which must be supported by detailed energy monitoring and analysis to
determine potential opportunities for saving;
- Staff training: in energy efficiency and carbon reduction can help change
behaviour in the workplace, to reduce unnecessary energy consumption;
- Communication: employee engagement and communications are an important
part of developing an organisation's culture of energy efficiency;
- Investment: energy efficiency investments often have to compete directly against
other demands for capital budgets. Budgets for energy efficiency should therefore
be ring-fenced to ensure they are not diverted, and a proportion of the energy
savings must be retained for further efficiency measures. Appraisal of
investments should be made on a whole life-cycle basis.
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Table 17 shows how best practice measures can be distinguished from good practice and
fair practice, when considering each of the above aspects.
Table 17. Energy management matrix
Best practice Good practice Fair practice
Energy policy,
strategy and action
plan
Energy policy and
action plan in place
and reviewed
regularly, with
active commitment
of top management.
Formal policy but no
active commitment
from top
management.
Un-adopted policy.
Organisational
structure
Fully integrated into
senior management
structure with clear
accountability for
energy
consumption.
Clear line
management
accountability for
consumption and
responsibility for
improvement.
Some delegation of
responsibility but
line management
and authority
unclear.
Performance
measurement
Fully integrated into
senior management
structure with clear
accountability for
energy
consumption.
Weekly performance
measurement for
each process, unit
or building.
Monthly monitoring
by fuel type.
Training Appropriate and
comprehensive staff
training, tailored to
identified needs.
Energy training
targeted at major
users following a
needs assessment.
Ad-hoc internal
training for selected
people as required.
Communication Extensive
communication of
energy issues within
and outside of
organisation.
Regular staff
briefings,
performance
reporting and
energy promotion.
Some use of
organisational
communication
channels to promote
energy efficiency.
Investment Resources routinely
committed to
energy efficiency.
Consideration of
energy consumption
in all procurement.
Same appraisal
criteria used for
energy efficiency as
for other cost
reduction projects.
Low or medium cost
measures
considered only if
payback period is
short.
Organisations should aim to achieve best practice measures across all of these aspects.
Without proper integration and strong communications across the organisation, energy
management becomes easily marginalised and undermined. Common weaknesses that
lead to poor energy management include the following issues (Carbon Trust, 2013):
- No active support from senior management;
- Lack of specific targets and commitments;
- Out-of-date documents/targets;
- EnMS is not supported by a strategy with the ability to deliver
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Target setting should be based on challenging but achievable targets that can be
determined through analysis of energy data and/or benchmarking against internal or
external performance.
The implementation of an EnMS should preferably be done according to formal standards
that require organisational improvements, such as ISO 50001. ISO 50001 is a standard
introduced in 2011, which specifies the requirements for establishing, implementing,
maintaining and improving an EnMS. It is modelled after ISO 14001 (environmental
management standard) and ISO 9001 (quality management), but differs in that it
requires an organisation to demonstrate that it has improved its performance. In
addition, adherence to these standards will allow energy management efforts to be
officially certified and recognised.
Achieved environmental benefits
EnMSs are useful where incremental gains are being sought through process refinement
and efficiency measures, without requiring radical redesigns of the process. While the
energy savings brought about by each individual measure are typically small, the
cumulative savings can be substantial. Organisations with a poorer starting point may
achieve more significant short-term improvements, but there are typically opportunities
still available even for firms that are relatively advanced in their techniques.
Appropriate environmental indicators
Appropriate environmental indicators are:
- Energy use (kWhe and KWht /year; / month, / week);
- Monitoring system for energy use – Y/N.
Cross-media effects
Energy management should be integrated with other environmental objectives and
consider the overall environmental impact. It should be noted that it may not be possible
to both maximise the total energy efficiency and minimize other consumptions and
emissions (i.e. energy may be required to reduce emissions to air, water and soil).
Operational data
Detailed examples are not provided in this BEMP but are available for specific BEMPS.
Linked BEMPs are:
- 2.2.6 Efficient ventilation;
- 2.2.7 Optimal lighting;
- 2.2.8 Energy and water savings of cooling circuits;
- 2.2.9 Efficient use of compressed air systems;
- 2.2.10 Reduction of standby energy of metal working machines;
- 2.3.7 Hybrid machining as a method to reduce energy consumption;
- 2.3.9 Reduce the energy for paint booth HVAC with predictive control;
- 2.3.10 Selection and optimization of thermal processes for curing wet-chemical
coatings on metal products.
Applicability
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Energy efficiency solutions can be deployed in all facilities, from incremental to in-depth
refurbishments. Regular walk-rounds are also recommended to identify new sources of
energy waste even in facilities that have already been optimized.
Economics
Detailed examples are not provided in this BEMP but are available for specific BEMPS.
In case of refurbishment or new production line, it is important to look to the total
lifetime cost rather than to investment costs.
Driving force for implementation
The drivers for energy efficiency are numerous, they include:
- Reducing energy costs;
- Reducing greenhouse gas emissions (which may also be associated with specific
taxes/levies/permits);
- Reducing emissions;
- Improving process efficiency;
- Improving working conditions and staff engagement;
- Improving public image.
Reference literature
Carbon Trust, 2013, Energy management, Available at:
http://www.carbontrust.com/media/13187/ctg054_energy_management.pdf, last
accessed 23th November 2015..
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2.2.6. Efficient ventilation
Description
Ventilation is an important process by which fresh air is circulated within a building.
When dust, fumes or mist is emitted from processes, such as evaporating lubricoolants
from machining, smoke from thermal processes like welding and forging and vapours
from painting booths more intense ventilation is needed. Ventilation for painting
processes (paint boots) requires specific measures as described in §2.3.9 (Reduce the
energy for paint booth HVAC with predictive control).
In a Fabricated Metal Products company, the most efficient methods of controlling
contamination in the occupied zone of the welding shop, and particularly in the breathing
zone of the operator or welder (with a manual welding), are:
- Enclosure of exhaust from the total welding process when automatic welding
machines are used;
- Enclosure of exhaust from the welding area enclosure when robotic welding and
material handling are used;
- Installation of local exhaust which captures the contaminants at or near their
source.
No local exhaust system is 100% effective in capturing fumes. However, it is important
to note that capture efficiency has a greater influence on air quality than filtration
efficiency. No filter device is effective until the fume is drawn into it. In addition, there
will be circumstances, because of the size or mobility of the welding zone, where
installation of local exhaust systems may not be possible. Also, local exhausts are
typically not efficient in removing fumes generated after welding at the heat-affected
zone.
General ventilation is needed to dilute pollutants not captured by the local exhaust
system and to dilute fumes generated after welding. General ventilation systems supply
make-up air to replace air extracted by local and general exhaust systems. Also, supply
air is used to heat and cool the building. The volume of outside air to be supplied by a
general ventilation system should exceed the volume of air exhausted by local
ventilation systems. Buildings should be pressurized to prevent air infiltration creating
cold drafts in winter, and hot humid air in summer. In addition to a local exhaust
system, a general exhaust system is used to evacuate air from the building.
Special attention should be given to ventilation of areas with grinding and polishing
operations. Especially, in the case with aluminium production. Air supply and exhaust
should be arranged in such a way as to create low velocity-low turbulent airflow
preventing dust dispersion in the shop. Low airflow, high vacuum exhaust systems built-
in grinding and polishing machines significantly reduce contaminant load on the building
(Zhivov A.M. et al., 2000).
To reduce the energy consumption of ventilation, different steps have to be taken30:
1. Understand the building and its air flows;
30 Ventilation must been seen as a part of the global HVAC (Heating, Ventilation and Air
Conditioning) of the building, where a comparable approach is advisable.
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2. Make an overview of sources of heat, humidity and pollutants (dust, fumes, etc.)
in the building;
3. Reduce emissions where possible;
4. Define the actual (and future) needs for ventilation;
5. Audit, to compare the defined needs with the current installation;
6. (Re)design the ventilation.
The installation of a ventilation system requires a profound study of the features of the
manufacturing site, the buildings and the processes installed. In particular, a good
understanding of the manufacturing site and the buildings ensures a satisfactory air
quality. Elements such as design, physical layout, mechanical systems, equipment and
installed manufacturing processes (the kind of installed manufacturing processes plays
an important role as well) and space usage are all essential and can affect air quality.
Furthermore, the air distribution system requires particular attention. The following
questions should be addressed, with care, in advance: "How does outdoor air get in?",
"Is the air filtered?", "How does air circulate throughout the building?". It is also
important to understand how spaces are designed and where walls (also knowing the
building materials and their thicknesses), furnishings and equipment are located.
Nevertheless, it should be mentioned that the building layout can create physical barriers
that impede the flow and distribution of air, which can impact the quality of air in a given
area (TSI, 2013).
The next step is to carry out an inventory of all sources of heat, humidity and pollutants
used on site. Different heating processes like forging, hot forming, welding, heat
treatment, surface treatments at elevated temperatures, etc. are applied by companies
in the Fabricated Metal Products sector. Open water systems, which can cause humidity
problems are limited, but a lot of process causes emit chemical products, which enter
the air as aerosols or vapour (e.g. the finishing step). Before defining the needs, several
methods for managing a pollutant source, are available once the source is identified,
including:
- Removing the source;
- Repairing the source so it no longer contributes with pollutants;
- Isolating the source with a physical barrier;
- Isolating the source using air pressure differential;
- Minimizing the time people/staff are exposed;
- In case of heat, is it an option to put a heat exchanger and reuse the heat;
- In case of heat vapour/steam, it is an option to condense them and reuse the
latent heat and product.
After the reduction of the ventilation requirements, by reducing of the sources of
pollution, the ventilation needs can be defined more precisely. However, the definition of
the ventilation needs should take into account actual legislations and standards 31.
After the precise definition of the ventilation needs, auditing can start. In certain cases
measurements of the air quality may be needed.
31. For instance, the EU directive (2010/31/EU) on the energy performance of buildings and the
WHO guidelines on indoor air quality (2010), are the most important policy instruments that
should be taken into account when the ventilation needs are defined.
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The last step is to design (or re-design) the ventilation system. To reduce the energy use
following techniques must been considered:
- Using variable speed drive motors for ventilation;
- Optimizing position and orientation of blowers;
- Controlling the air volume in function of the ventilation needs.
Often systems are designed in a way that enables ventilation from multiple (similar)
workstations all connected to one dust collector, filter and fan. Correspondingly, the
appropriate size of the fan motor is chosen based on the theoretical maximal ventilation
need. However, data from real factories show that, typically, less than 50% of machinery
is working at any given time; therefore, 50% of machinery is not producing dust (fume,
mist); despite this fact, suction continues from all machines (Litomisky, 2006).
These on-demand systems are already being used in the chemical, metal, and
woodworking industries, achieving average electricity savings of 68% over unregulated,
classical systems. The basic idea is simple: equip each workstation with a sensor that
detects when ventilation is necessary, and use a motorized gate to close the ventilation
duct when ventilation is not necessary. Then the RPM of the fan can be adjusted to
achieve a proper air volume in the ducts.
If dust or other material are to be transported through the ducts, then it is necessary to
maintain a set minimum velocity in the ducts to prevent the material from settling; also,
minimum negative pressure should be maintained to overcome pressure losses in the
ducts. When gates at non-working workstations are closed, air volume and subsequently
air velocity in the main duct will drop and dust can settle. An on-demand dust collecting
system solves this problem by using a PLC (industrial computer) that calculates the
necessary air volume and the necessary negative pressure based on information from
the sensors. The PLC adjusts the RPM of the fan accordingly, and it also opens additional
gates at non-working machinery if this is necessary for maintaining proper air velocity.
Ventilation can be regulated by monitored demand, configuring the machine shop
operations such to avoid peak draws and more energy efficient operation. Installed
venting capacity can be optimized taking the effective need into account instead of an
on/off regulation. Demand data capture and controls on plant level demand requires side
wide coordination. The dimensioning of the venting installation based on the effective
demand. Comparing utilities demand over time with utilities cost curve allows for total
cost of ownership reduction.
Lowering the air extraction volume reduces also the need for heating or air conditioning
in the plant. This generates additional environmental benefits (less energy for heating or
air conditioning needed).
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Figure 29. Fan Law: at 50% reduction of air-flow (which is achieved by automatically
closing gates on non-operating machinery), fan motor will consume only 12.5% of
electricity of what is required when suction is running at all workstations. This is a
reduction of 87,5% (Litomisky, 2006)
Achieved environmental benefits
The major benefit is the reduction of energy use. This leads to an overall reduction of the
indirect greenhouse gases (GHG) emissions of companies in case the electricity is
coming from conventional power plants (from fossil fuels)32.
By implementing this technology, companies will reduce their direct energy use for
ventilation with 20 to 70% (Figure 29, Schlosser, 2011).
In addition, the implementation of demand management processes provide better
insights in real ventilation extraction needs resulting in down sized installations. Not all
workstations or machining processes operate at 100% during the total shift time. Hence,
a well-controlled ventilation results also in a better indoor air quality. Furthermore, it can
also reduce energy consumption for heating during winter and cooling during summer,
as less air is extracted from the production halls (Siemens, 2010).
Lowering of ventilation also leads to noise reduction due to lower fan speeds and lower
extraction volumes.
Duct diameters are smaller when demand controlled ventilation is applied because they
are optimized for example for 70% of air volume.
Appropriate environmental indicators
Appropriate environmental indicators are:
- Type of ventilation system: demand driven – Y/N;
32 The energy mix of each company might be different, hence should be carefully
examined.
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- Use of energy per m³ building (installed kWh or m³/hour): dimensioning of installed
ventilation capacity. The capacity can be compared before and after implementation
of demand driven ventilation.
- The effective air volume extracted from the building. This can be measured and
compared over time periods or production batches.
o Extracted air per hour (m³/h) or per shift is a good indicator in case of a
rather stable production process and volume.
o Extracted air per produced batch of material X, Y, Z produced (m³) is a better
indicator in case of a variable production process and volume.
Cross-media effects
There are no cross-media effects due to efficient ventilation in manufacturing plants.
Operational data
Each workstation must be equipped with a sensor and an automatic air valve. The sensor
will detect if ventilation is needed or not. To control the ventilation, all the valves will be
steered by a central process unit.
Figure 30: Left: Unregulated system with duct system directly connected to dust
collector, fan-motor combination. Right: On demand system with sensors to close duct
gates. VFD controlled fan motor controlled by PLC (Litomisky, 2006)
A minimum velocity in the duct is required to prevent dust particles settling in the duct
(instead of in the dust collector). The pressure drop needs to be controlled and a process
unit adjusting fan speed and/or opening/closing additional gates to assure a proper air
speed needs to be installed.
The ‘Duct Optimizer software’ exist is available to simulate and optimize the duct system
for any given application.
At Daimler Truck the plant ventilation was reduced from >30 Nm³/h/m² to
17 Nm³/h/m², as the machine ventilation was reduced from 1,800 Nm³/h/m² to
720 Nm³/h/m². A saving of 50% was measured (Schlosser, 2011).
Case study: NE08 (BE): upgrade of the ventilation system at a welding training centre
building (Acuna, 2014).
Technologies implemented:
- Demand-controlled ventilation strategy with intelligent system controls;
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- Current transformers (to detect welding booth operation);
- Motion detectors (to detect welding booth occupancy);
- Pressure sensitive mats;
- Variable frequency drive fan motors;
- High efficiency fan motors.
The ability of the system to adapt to the variable extraction/make-up air demands offers
the possibility for energy savings. The new system will enable the reduction of both
extracted air volumes and make-up air volumes. Less air to move means less electricity
required to operate extraction and make-up air unit fans. In turn, less natural gas will be
required to heat the make-up air during colder months. GHG emissions reductions will
result from lower electricity and natural gas consumption.
Total energy savings reported (measured, normalized savings after a few months of
operations):
- 6,500 GJ/yr of natural gas;
- 800,000 kWh/yr of electricity;
- 9,500 GJ/yr or 2,550,000 eKwh/yr of total energy conservation per year;
- 150 kW reduction in electricity demand.
Case Study – Aerospace Component Manufacturing Plant – demand control ventilation
combined with other energy efficiency improvements (Rappa, 2012).
Analysis:
- Manufacturing make-up air and exhausts analysed;
- 150,000 – 250,000 CFM of makeup air supplied and exhausted annually;
- 1,700,000 kWh, 32,000 mmBTus, $435,000 annually;
- 4-7 air changes per hour.
Energy efficiency improvements:
- exhaust heat recovery;
- demand control ventilation;
- variable speed drives;
Results:
- 1,100,000 kWh, 17,200 MMBtus.
Applicability
This BEMP can be installed in all manufacturing processes in the Fabricated Metal
Products sector:
- Forging processes;
- Welding processes;
- Paint spray processes (paint booth) - finishing33 -(see §2.3.9: Reduce the energy
for paint booth HVAC with predictive control)
- Machining.
The installation of an on-demand system is more complex than a conventional
ventilation unit. The investment costs and maintenance cost are higher than for a
33 BEMP Reduce the energy for paint booth HVAC with predictive control, is more
specific.
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conventional system, as it needs steering, sensors, etc. An on-demand systems is easier
to implement in new facilities, but also applicable for existing facilities.
Economics
Savings through lower need of heating or air conditioning are typically two times higher
than the fan electricity savings (depending on geographical location, operating hours and
energy cost) (Litomisky, 2006).
Reduction of energy cost: 20 to 80% compared to on-off non demand controlled
ventilation (Litomisky, 2006; Siemens, 2010 and Schlosser, 2011).
Figure 31. Savings by on-demand ventilations (Litomisky, 2006)
Case NE08: upgrade of the ventilation system at a welding training centre building
(Acuna, 2014).
Savings:
- At 2014 energy rates: $150,000 per year (including demand charges);
- Note: There are also approximately $5,000 to $10,000 per year of predicted
maintenance cost savings and an unknown $ figure for shielding gas cost savings.
Case Study – Aerospace Component Manufacturing Plant – demand control ventilation
combined with other energy efficiency improvements (Rappa, 2012).
Savings:
- Annual savings: $230,000;
- Payback time: less than 2 year.
Driving force for implementation
The main driving forces for implementation are:
- Reduction of energy consumption;
- Cost savings;
- Reduction of carbon footprint;
- IAQ (Indoor Air Quality) and employee well-being.
Reference organizations
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December 2015 143
British Columbia Institute of Technology, did an upgrade of the welding training centre
building. They installed on demand controlled ventilation.
http://commons.bcit.ca/factorfour/2014/04/12/welding-ventilation-energy-efficient-
upgrade/ , last accessed on 28th September 2015.
Mercedes-Benz Wörth Plant (Germany) – production of trucks; installed demand
controlled ventilation.
http://www.mercedes-
benz.de/content/germany/mpc/mpc_germany_website/de/home_mpc/trucks_/home/dri
vers_world/plant/woerth.html, last accessed on 28th September 2015.
Reference literature Acuna, C., 2014, British Columbia Institute of Technology, Welding Ventilation Energy
Efficient Upgrade, available online at:
http://commons.bcit.ca/factorfour/2014/04/12/welding-ventilation-energy-efficient-
upgrade/, last accessed on 28th September 2015.
Directive 2010/31/EU of the European parliament and the council of 19 May 2010
on the energy performance of buildings.
Litomisky, A., 2006, Exhaust ventilation energy saving in car manufacturing and other
industries. 29th World Energy Engineering Congress, Washington D.C., 2006, available
online at:
http://www.kraemertool.com/store/pc/catalog/weec-washington-on-demand-ventilation-
by-ales-litomisky.pdf, last accessed on 28th September 2015.
Rappa R. F., 2012, Metal Finishing Roundtable NYSERDA Opportunities for Industry, May
17, 2012, available online at:
http://www.rit.edu/affiliate/nysp2i/sites/rit.edu.affiliate.nysp2i/files/nyserda_2012_ipe_
programs_metal_finishing_roundtable_051712.pdf, last accessed on 28th September
2015.
Siemens, 2010, Demand-controlled ventilation, control strategy and applications for
energy-efficient operation, available online at:
http://www.google.be/url?sa=t&rct=j&q=&esrc=s&frm=1&source=web&cd=1&ved=0CB
8QFjAA&url=http%3A%2F%2Fwww.siemens.com%2Fbt%2Ffile%3Fsoi%3DA6V1023907
2&ei=q_k4VZzOKIbvywOgyoEI&usg=AFQjCNGn7ycMC-
0k9qo1NqARqR2iIZ1Hlg&sig2=FHoCviqLD3ImTCxLAFnMdw&bvm=bv.91427555,d.bGg
last accessed on 28th September 2015.
Schlosser, R., 2011. BEAT project (Fraunhofer). Energy and resource efficiency in
production. Seminar “Produceer met minder energie”. Zwijnaarde, 2011, available online
at:
http://www.slideshare.net/sirris_be/produceer-met-minder-energie-energy-and-
ressource-efficiency-in-production-ralf-schlosser, last accessed on 28th September 2015.
TSI, 2013, Indoor air quality handbook, available online at:
http://www.tsi.com/uploadedFiles/_Site_Root/Products/Literature/Handbooks/IAQ_Hand
book_2011_US_2980187-web.pdf, last accessed on 28th September 2015.
Background document on best environmental management practice in the Fabricated Metal Products sector
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WHO, Indoor Air Quality – website, available online at:
http://www.euro.who.int/en/health-topics/environment-and-health/air-
quality/policy/who-guidelines-for-indoor-air-quality, last accessed on 28th September
2015.
WHO, 2010, WHO guidelines for indoor air quality: selected pollutants, available online
at:
http://www.euro.who.int/__data/assets/pdf_file/0009/128169/e94535.pdf, last accessed
on 28th September 2015.
Zhivov A.M. et al., 2000, Ventilation guide for automotive industry, Penton Media, 223p,
available online at:
http://eber.ed.ornl.gov/pub/Ventilation_Guide.pdf, last accessed on 28th September
2015.
Background document on best environmental management practice in the Fabricated Metal Products sector
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2.2.7. Optimal lighting
Description
Metal products fabrication requires, just like any other industrial process, light e.g. for
the product quality check process and safety reasons. The energy consumption for the
light system of a production hall is a significant contributor to the overall energy
consumption (significance of the contribution depends on the energy intensity of the
other energy consuming activities in the company). Energy needs for lighting increases
e.g. by increasing operating hours (two or three shifts) or surfaces, and when using
older lighting technology (e.g. high pressure sodium lamps). In some Fabricated Metal
Products companies lighting is responsible for 10% of the total energy consumption
(Dialight, 2015).
Optimization of existing plants can be an opportunity to reduce costs and the carbon
footprint.
To reduce the energy consumption of lighting, different steps have to be taken:
- Perform a lighting study, to define the actual (and future) needs of light;
- Perform an audit, to compare the defined needs with the current installation;
- Perform a lighting plan, to define what is the optimal solution (light system,
fitting, lamps, etc.) to fulfil the needs.
In case of new installations, only step 1 and 3 are necessary.
A lighting study defines the light needs for each activity. Depending on the type of
activity (precision work or rough work) more or less light is needed. The latter is defined
in standards EN 12464-1 (indoor) and -2 (outdoor) (2011). The lighting study takes into
account the different amount of daylight for each room/hall during day/night,
week/weekend, summer/winter and the different needs during each period. The lighting
study gives also an overview of the light duration for each location (e.g. minutes for
corridors, only when people pass, or the whole day for workspaces).
During an audit a comparison between the defined lighting needs and the actual lighting
will be done.
A lighting plan gives the optimal solution (e.g. amount of luminaires and luminous
intensity) for each location in the company. Daylight must be chosen as a first option.
Lighting plans aim to indicate the right solution for each component of the light systems.
In case of new buildings, lighting studies and lighting plans must be part of the design.
Activities and the placement of windows and dome skylights must be planned in function
of the orientation of the sun.
During step 3, the different components of the light system are defined. Taking into
account:
- the surroundings (building, room, workplace, street, parking place, etc.);
- the choice of suspension of the luminaires (ceiling, wall, pole, etc.);
- the lighting calculation in accordance with the appropriate standard, including
the optimization to the lowest energy consumption;
- the choice of a lighting management system including sensors, controls and
communication network;
- the choice of the luminaire including light source, ballast and optic;
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- the choice of an emergency escape lighting system;
- the installation and commissioning of the whole system;
- lighting control system;
o Lighting control is available for almost all lighting applications and some
examples are listed below.
daylight dependent lighting control;
movement dependent lighting control;
constant illumination level;
building management system;
In this system light and energy control is integrated at building level. For
instance a system that can simultaneously apply six different energy
management strategies in order to save as much power in a building as
possible, comprising:
intelligent time control;
daylight dependent system;
movement detection;
individual control;
limitation of the peak output.
To design lighting systems/lighting plans there are different design and calculation
software available.
Different economic models are possible to finance relighting projects. Fabricated Metal
Products companies can choose to finance their own relighting projects or they can
prefer to outsource these activities. A third option is the servitisation of light. In that
case, the company pays for a light service, while the contractor provides the lighting
infrastructure.
Achieved environmental benefits
New light systems result in a significant reduction of the electricity consumption. This
leads to an overall reduction of the indirect greenhouse gasses (CO2) emissions.
Based on the first results of EU Ecodesign Preparatory Study on Lighting Systems
(Vantichelen et al., 2015) the industry34 can save up to 70% on indoor lighting and up to
90% on outdoor lighting. The whole European industry (EU-28) consumes 18 TWh for
indoor and 6 TWh for outdoor lighting per year. There are no detailed numbers available
for the Fabricated Metal Products sector. Other sources (Encon, 2015) give savings
potentials for electricity of 50% to 80% based on cases studies in different industrial
sectors.
Appropriate environmental indicators
34 This study will provide the European Commission with a technical, environmental and
economic analysis of lighting systems as required under Article 15 of the Ecodesign
Directive 2009/125/EC. The study is carried out for the European Commission, DG
Energy under specific contract N° ENER/C3/2012-418 Lot 1/06/SI2.668525,
implementing framework contract ENER/C3/2012-418 Lot 1. The study team effectively
started in January 2014 and is expected to be finished in December 2016. The draft only
contains a quick scan for the whole industry. Later, detailed study will be made for some
subsectors in the industry.
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An appropriate environmental indicators is the electricity consumption (e.g. in kWh/m²
lighted floor per year) for the lighting of the Fabricated Metal Products company is a
general indicator.
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Cross-media effects
Based on measurements, 98% of the lighting in workspaces is insufficient comparing to
the EU standard. When the original lighting installation is not in line with the actual
standards on Lighting of work places, more light can be needed (Technische Unie, 2015).
Besides better lighting, relighting can lead to more light. Thus, the overall result can be
a better lighted company, without energy savings.
Operational data
The total consumption of electricity decreased for about 66% in a warehouse of
Black&Decker, as lighting was the main electricity consumer. The main steps were:
performance of a lighting study and audit, replacement of light armatures, placement of
movement sensors (react when fork-lift truck arrives), and placement of dimmable
ballasts to reduce the light intensity to 3% of the maximum capacity. The study results
in more light where it is needed by employees. The whole project was awarded the EU
GreenLight certificate (Encon, 2015).
Case study: ALANOD Aluminium-Veredlung (DE)
At ALANOD Aluminium-Veredlung a new lighting system in the warehouse and assembly
facility lead to a reduction of 67% of the electricity consumption of lighting. The payback
period was 1.1 year (ETAP, 2011). In other companies, new light systems lead to
comparable reductions (50% at John Deere, 60% at Verhoef; Philips, 2011 and 2015).
The savings were reached by a combination using other lamps, reflectors and using a
management system to turn on/off lights.
Case Study: Martisa manufacturing (ES), producer of metal pieces (Dialight, 2015)
With the metal processing machinery pumping so much energy, the 32 x 400 W high
pressure sodium (HPS) lights in the 1288 sqm Martisa facility were subject to frequent
dimming and flickering, so the management were looking for a more robust lighting
solution. The performance instability of the HPS was also generating irregular colour
rendition areas varying between 118 and 270 lux at floor level.
Under 150W DuroSite LED High BaysUnder 400W High Pressure Sodium lighting Further
problems arose when the lights took ten minutes to re-strike following power outages.
Maintenance was also an issue, as the HPS lights were mounted at a height of 9 metres,
ran ten hours a day, five days a week and had to be replaced every 10,000 hours, each
at a unit replacement cost of € 50 plus the use of a mobile elevation platform that cost
€ 100 per day.
Martisa is now enjoying the immediate benefits of 69% reduction in lighting energy
consumption and reduced carbon emissions from solid-state LED High Bays that suffer
no flickering or dimming effect from the amount of energy being pumped by the
machinery. The lux level is now steady at 200 at floor level, giving improved and
consistent colour rendition, while the LEDs’ instant-on ability means that there is no re-
strike delay following power outages. Carrying a 5-year continuous performance
warranty and with an expected lifetime of 60,000 hours, the LED lighting has also
greatly reduced the maintenance burden and cost.
Case Study: Olympus KeyMed (UK) - producer of metal medical equipment (Dialight,
2015)
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December 2015 149
Olympus KeyMed’s Southend-on-Sea facility comprises warehousing and manufacturing
with sheet metal as well as a paint shop. Here it not only produces medical and industrial
products, but it is also the sole UK point of importation and distribution of all Olympus
products. With over 100 metal halide high bay lights across our 3,380 square metre
facility, measurements shows that the 400 W high bays were actually operating at 440
W and accounting for 10% of our total energy usage.
Olympus KeyMed also found that the metal halide high bays were lasting two years at
best or 15,000 hours on average, though replacement cycles could be shorter as a result
of heat generated and accumulation of dirt. Additionally there was the ongoing chore of
inspecting for failed lights and servicing those that had failed.
After researching the LED market, and with the recommendation of energy consultants a
lighting plan was made. Mounted at a height of 12 m, the metal halide high bays were
replaced one-for-one with 150 W LED armatures. Significantly this led to the discovery
that the actual consumption of the LED lights including drivers was 5-10% less than the
expected 150 W – an additional energy saving bonus while maintaining the same light
level but immediately reducing energy usage by over 68%. As a result, Olympus is now
on target to cut carbon emissions by 85 tonnes per year.
In the manufacturing side of the business the lighting runs 24 hours/5.5 days a week,
while in logistics it runs 14 hours/5 days a week and Olympus KeyMed is introducing
sensor control in both units to deliver further energy and carbon reductions. The control
software has a payback periods of less than 4 years.
Re-strike time had been an issue in all areas with the metal halide lights, especially in
the inspection area, so low level fluorescents had been installed as back–up to avoid
production downtime. With the instant-on ability of the LED High Bays these back-up
lights can now be taken out.
Applicability
The applicability of optimal lighting is generally applicable in all Fabricated Metal
Products companies. The potential impact increases with duration of the light needs.
Economics
Economics highly depend on the size of the relighting project. The GreenLight
programme35 (EU, 2015) provides calculation spreadsheets36 for assessing the cost-
35 The GreenLight Programme is a voluntary pollution prevention initiative encouraging non-
residential electricity consumers (public and private), referred to as Partners, to commit towards
the European Commission to install energy-efficient lighting technologies in their facilities when (1)
it is profitable, and (2) lighting quality is maintained or improved. GreenLight was launched on 7
February 2000 by the European Commission Directorate General Energy & Transport.
The objective of the GreenLight programme is to reduce the energy consumption from indoor and
outdoor lighting throughout Europe, thus reducing polluting emissions and limiting the global
warming. The objective is also to improve the quality of visual conditions while saving money. 36 The spreadsheet can be downloaded from the link below:
http://iet.jrc.ec.europa.eu/energyefficiency/sites/energyefficiency/files/files/documents/GreenLight
/gl_calc3.xls
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December 2015 150
effectiveness of one (or two) energy-efficient lighting system(s) compared to one
conventional new installation. Other companies provide comparable spreadsheets
(Energie+, 2015).
Different economic models are possible to finance relighting project. Fabricated Metal
Products companies can choose to finance their own relighting projects or they can
prefer to outsource these activities. A third option is the servitisation of light. In that
case, the company pays for a light service, while the contractor provides the lighting
infrastructure.
In case sector companies invest in relighting, the payback time varies between 1 and 4
year, taking into account all costs: study work, new lamps, ballasts, etc. and installation
costs (Encon, 2015). The payback time depends on the original situation.
The service supplier of ‘light’ has the incentive to reduce the lighting cost for its client
(mainly through the same or higher light performance for a lower energy cost) on the
one hand, and to design/search for lightning products with a longer lifetime, and an
optimal use of daylight. The light as a service concept allows the Fabricated Metal
Products companies to reduce the risk on two levels. First the technological risk, this risk
is taken over by the light supplier who is under control of the lighting product design
process. Secondly the financial risk for the company is reduced, since no investment is
needed. The light provider has incentives to improve and optimize the product design for
longevity and to reduce the energy consumption by introducing calendar control, day
light sensors, presence sensors etc. Even so the supplier can capture data on the
product use and provide the company user profiles. This can lead to further energy
efficiency improvements.
An example of servitisation: In the CycLED-project (2015) a case was elaborated in
which, by changing ‘classic’ illumination through LED-technology, over a period of 12
years, costing 208 099 euros on the service contract (all materials and services included)
(the classic illumination would have cost 320 152 euros in the same period). This is a
yearly saving of 35% on operating costs. Moreover, through higher energy efficiency of
the chosen technology, with constant energy cost, an extra of 112 053 euros could be
saved (146 374 euros with the projected 5% increase of electricity prices per year).
Driving force for implementation
Increased energy costs for companies make relighting an increasing interesting option.
The light quality is increased, having a positive effect on working behaviour of
employees (Schlangen et al, 2014). In case of servitisation of lighting, companies can
focus more on their core activities, reducing risks and resources dedicated to lighting
optimization.
Reference organizations
ALANOD Aluminium-Veredlung – producer of anodised and PVD coated aluminium coil
Relighting of warehouse and assembly facility leads to a reduction of 67% of the
electricity use of lighting. The payback period is 1.1 year.
Black & Decker – producer of do-it-yourself tools
They got the European GreenLight Main Endorsers certificate for the relighting of their
distribution centre.
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December 2015 151
Martisa manufacturing (ES), producer of metal pieces (Dialight, 2015).
http://www.martisa-components.com/ca/
Olympus KeyMed, UK, producer of metal medical equipment (Dialight, 2015):
http://keymed.co.uk/index.cfm
John Deere – world leader in agricultural technology
The company refurbished the lighting at its 42 hectare factory site to save energy and to
improve at the same time working conditions. The workshops were fitted with reflector
light carriers with TL5 lamps. A light management system with daylight-dependent
control combines high efficiency with low maintenance. In some buildings the solution
has achieved energy savings of up to 50% with visibly better lighting and positive
employee feedback (Philips, 2011).
Verhoef – production of all types of aluminium lifeboats, aluminium (patrol-)boats as
well as other aluminium products for the shipbuilding industry such as gangway systems.
Relighting of the production hall results in savings of 60% on electricity for light and a
payback period: 1.5 year (Philips, 2015).
Volvo Cars - productions of cars and trucks.
In their production plan in Ghent, a relighting is been done: the lighting has been divided
up into a large number of small zones, each of which can be independently switched on
and off. General lighting and process lighting turns off automatically in each zone
depending on the amount of light coming in through the new skylights. All manual
switches in the plant are being removed. Switching times per zone have been adapted.
In irregular situations, such as night working, weekends or layoff, lighting can be
controlled manually for each zone from a central location. (Volvo, 2012)
Reference literature
CEN, EN 12464-1; Light and lighting – Lighting of work places – part 1: indoor work
places, 2011.
CEN, EN 12464-2, Light and lighting – Lighting of work places – part 2: Lighting of
outdoor work places, 2011, available online at:
http://standards.cen.eu/dyn/www/f?p=204:110:0::::FSP_PROJECT,FSP_ORG_ID:30549
,6150&cs=1A676429B1AD101CE9CC2744517E0E886, last accessed on 11th September
2015.
Cyc-led, 2015, available online at:
http://www.cyc-led.eu/index.php, last accessed on 11th September 2015.
Dialight, 2015, Case Study: Martisa manufacturing in Barcelona, Spain, available online
at:
http://www.dialight.com/Assets/Brochures_And_Catalogs/Illumination/MDEXBRCX001.p
df, last accessed on 11th September 2015.
EEA, 2011, Trends in energy GHG emission factors and % renewable electricity (EU-27),
available online at:
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 152
http://www.eea.europa.eu/data-and-maps/figures/trends-in-energy-ghg-emission, last
accessed on 11th September 2015.
Encon, 2015. Case study Black & Decker, available online at:
http://www.encon.be/nl/our-clients-case-studies-detail.aspx?ID=41247cf5-dbbd-4ad3-
8bb6-b9af33ca3d0e, last accessed on 20th April 2015.
Energie+, 2015, available online at:
http://www.energieplus-lesite.be/index.php?id=1, last accessed on 20th April 2015.
ETAP, 2001, Case study: ALANOD Aluminium-Veredlung, available online at:
http://www.etaplighting.com/Reference.aspx?id=7138&LangType=1033, last accessed
on 20th April 2015.
EU, DIRECTIVE 2010/31/EU of the European Parliament and of the Council of 19 May
2010 on the energy performance of buildings, available online at: http://eur-
lex.europa.eu/legal-content/EN/TXT/?uri=CELEX:32010L0031, last accessed on 20th April
2015.
EU, JRC. GreenLight programme (2015), available online at:
http://iet.jrc.ec.europa.eu/energyefficiency/greenlight, last accessed on 20th April 2015.
Fetters, J.L.; (1997) The handbook of lighting surveys & audits. ISBN O-8493-9972-6.
Philips, 2001, Industries, feel what light can do for you, available online at:
http://www.lighting.philips.com/pwc_li/main/application_areas/assets/pdf/Industry%20b
rochure%202011%20INT.pdf , last accessed on 20th April 2015.
Philips, 2015, Benefits greatly for master LEDtube, available online at:
http://www.lighting.philips.com/main/cases/cases/manufacturing/verhoef-access-
technology.html, last accessed on 20th April 2015.
Schlangen L., Lang D., Novotny P., Plischke H., Smolders K., Beersma D., Wolff K.,
Foster R., Cajochen C., Nikunen H. Bhusal P., Halonen K., 2014, Lighting for health and
well-being in education, work places, nursing homes, domestic applications and smart
cities. Accelerate SSL. Innovation for Europe. 75p, available online at:
http://lightingforpeople.eu/wp-content/uploads/2014/02/SSLerate-3.2-3.4-v4.pdf, last
accessed on 20th April 2015.
Technische Unie, Werkplekverlichting, available online at:
https://www.mijntu.nl/portal/themas/verlichting/normen-richtlijnen-
verlichting/werkplekverlichting/, last accessed on 20th April 2015.
Van Tichelen P., Chung Lam W., Waide P., Kemna R., Vanhooydonck L., Wierda L., 2015,
Draft document: Preparatory study on lighting systems 'Lot 37' Task 0 & 1 SCOPE WITH
QUICK SCAN, available online at:
http://ecodesign-lightingsystems.eu/documents, last accessed on 20th April 2015.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 153
Volvo, 2012, Volvo Europa truck NV, First CO2-free company in Belgium and the first
CO2 -free automotive factory worldwide, available online at:
http://www.volvotrucks.com/SiteCollectionDocuments/VTC/Corporate/About%20us/Envi
ronment-2012/CO2_gent_eng.pdf, last accessed on 20th April 2015.
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December 2015 154
2.2.8. Energy and water savings of cooling circuits
Description
To optimize cooling circuits and reduce the energy used a systematic approach is
necessary:
1. Define the actual (and future) needs for cooling, reduce the demand where
possible;
2. Audit, to compare the defined needs with the current cooling installation;
3. (Re)design cooling installation.
Below the approach is described for the machine shops, as cooling circuits in machine
shops are often passed on water circuits.
Step 1: Define needs and reduce the demand
- If the primary needs can be reduced by selecting other machining, pumps, etc.
then this has to be done in the first step. For instance, over-specified fixed seed
pumping capacity versus demand driven (VFD) pump capacity control.
- Largely abandoning the use of cutting fluid (e.g. minimum quantity lubrication) is
unfortunately not often achievable due to quality issues. However, optimizing
spray nozzles for grinding and reducing the cutting fluid pressure for internally
cooled drilling and milling tools is often possible.
- Usually, the cutting fluid supply continues during downtime so that the machine
can maintain a steady temperature. The machine is therefore extensively flooded
with cutting fluid. By optimizing the restart process and improving scheduling,
temporary shutdowns are made possible. This is linked with BEMP 2.3.3 on
cutting fluidsError! Reference source not found..
- Reduce the temperature specifications where possible. When there are large
temperature differences between the cutting fluid and its surroundings, the cost
of the re-cooling process increases significantly. With oil-based cutting fluids,
adjusting the temperature to the room (or ambient condition) becomes an option.
- If the primary needs can be reduced by selecting other machining, pumps etc.
this has to be part of the first step. For instance, larger pumps are especially used
in central systems and to internally cooled tools. The pressure is usually kept
constant by a bypass regulator. Regulating the pump speed (through Variable
Frequency Drive (VFD)) instead provides significant savings. Centralized cooling
for multiple machines make system optimization possible.
- Last but not least, the total cooling need of the factory is not always the sum of
all potential maximum cooling needs. Timechart the cooling need and identify
where cooling needs are to be added up and where cooling needs can be
flattened out by shifting over time (in particular by looking at what processes are
largely dependent on the outside temperature, and which are almost independent
of outside temperature). The approach below explains this process.
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December 2015 155
Figure 32. Plant and heat pump load (Heemer et al, 2011)
After the audit step (step 2), the optimum cooling equipment (step 3) must be selected.
- When designing the system, priority should been given to cooling optimization at
the machine level instead of cooling optimization at the plant level.
- Avoid designing the system based upon ‘standard’ cooling equipment. The most
energy and water efficient solutions should get preference.
- Select the optimal cooling tower system. Trade-offs need to be made between
energy efficiency, water saving and noise reduction. In general, axial fan
equipment is more energy efficient then radial fan configurations, while noise-
wise the opposite is true. Table 18 gives an overview of the advantages and
disadvantages of different types of cooling towers.
- If possible, open water cooling systems should be avoided, as the cooling water
can become polluted and needs treatment before discharge.
Table 18. Different type of cooling towers and their advantages and disadvantages,
(based on Baltimore Aircoil, 2015; Seattle Public Utilities, 2015; US Department of
Energy, 2011)
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December 2015 156
Energy use Sound level Operational
safety (Hygiene)
Water saving
Fan type
Axial fan (forced draft)
more efficient fan types
Reduced speed
and specific fan
configuration to
reduce sound
reduce also the energy efficiency
Radial fan
(induced draft)
less efficient
fan types
easier to reduce
sound (by using
intake and
discharge sound attenuators)
Cooling tower Architecture
Counter flow in general more
difficult to
access tank for
cleaning and maintenance
Cross flow
in general
easier to access
fill for cleaning
and maintenance
Cooling system architecture
open system
in general less
sound effective
due to sound of falling water
higher risk on
water due to larger supply
low potential for
water saving
closed system potentially lower sound emission
More potential for water savings
The most efficient cooling towers are hybrid architectures and include controls directing
the cooling water to a closed air cooled heat exchanger, to an open cooling tower or
sequentially to both.
Achieved environmental benefits
By using a properly working chilled water system design, the energy and water
consumption can be reduced.
By using less water, the water treatment cost can often be reduced. Especially in open
cooling systems the water volume to be treated (softening, filtering) is reduced.
Furthermore, the noise level of the system can be reduced significantly, benefiting
employees as well as other actors like neighbouring companies, neighbouring families,
wildlife (in case of night operations), etc.
In the Bosch metal cutting departments in Feuerbach and Bamberg the systematic
approach resulted in a total savings of 4,000 MWh per year (Energiewende180, 2015).
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Appropriate environmental indicators
Appropriated environmental indicators are:
- Energy consumption (kWh/year for cooling);
- Water consumption (m³/year for cooling);
- System optimization versus sub optimal machine level optimization – Y/N;
- Is there a sound reduction? Y/N.
Cross-media effects
Open or semi-open cooling circuits can lead to microbiological contamination. Therefore
water treatment and control are needed. Legionella (the bacterium Legionella
pneumophila) can grow in the cooling water within the typical temperature range of open
cooling systems.
Legionella pneumophila is a ubiquitous organism. It appears in almost every ground and
surface water. The organism survives typical chlorine disinfection for potable water and
consequently can appear in finished water distributed to homes and industry.
Good practices and guide lines exist to prevent legionella to occur (e.g. Guideline: Best
Practices for Control of Legionella from the Cooling Technology Institute) .
Operational data
Adiabatic cooling (Figure 33) based on a classic dry cooler is an alternative that does not
provide the possibility for evaporative cooling, but does have advantages over dry
cooling:
Highly efficient air pre-cooling giving up to 40% additional capacity over a fully dry air
cooled alternative (Baltimore Aircoil, 2015):
- Up to 80% humidification of air compared with industry’s norm of 50-70%;
- Once-through, minimum flow water system with no scaling, corrosion or
microbiological growth potential and so no requirement for water treatment;
- Year round lower condensing temperatures using pre-cooling mode only when
needed, saving chiller power and reducing emissions;
- Low noise levels;
- No use of toxic chemicals;
- Water savings of at least 70% compared with cooling towers;
- No potential for legionella proliferation and no generation of aerosols or water
droplets thus avoiding any risk of legionellosis.
In the VW plant in Salzgitter VFD drives are installed (Grundfos, 2015). These
frequency-controlled pumps offer a number of benefits compared to fixed-speed pumps,
in addition to energy savings:
- The frequency converter allows simple wiring procedures;
This is especially the case when using VFDs with an integrated frequency
converter's lower range of pump power, typical available up to 22kW.
- There is no need for energy-consuming transfer ports, line throttling and valve
controls to set the duty point;
- Time-consuming adjustment work is no longer required in the event of changes to
the production line;
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December 2015 158
- Remote control and parameter adjustment device can be used to monitor
changes (monitors are available on the market) and save current operating states
for the individual pumps;
- No pressure surges occur during system warm-up, thanks to soft start
technology, resulting in a positive impact on tool lifetime.
Dry cooling
Cooling the liquid by the
dry finned coil (2) for
example in winter
conditions when the outside
temperature allows dry
cooling.
Adiabatic cooling
The fluid is cooled in the dry
finned coil (2) but the air flowing
over this dry coil is saturated
with water which increases the
cooling capacity. This is often
possible in the spring and
autumn weather conditions.
Wet-dry operation
In summer the fluid
can be pre-cooled
through the finned top
coil (2) and cooled
through evaporative
cooling in the wet coils
(3).
Figure 33. Hybrid systems offers different operation mode: for dry, adiabatic and wet-
dry cooling (Baltimore Aircoil, 2015)
Applicability
The approach is fully applicable for all SMEs, but also for large scale companies.
All companies have cooling needs for one or more machines or other applications and
processes like forging, etc.
Although the principles and approach for seeking energy and water consumption
reductions in the water (coolant) circuits are logical, SMEs might desire support from
external partners. For most Fabricated Metal Products SMEs, cooling management is not
a high priority. In this context, capacity building via subcontracting is often more
attractive than going through a learning curve alone.
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December 2015 159
Economics
Most of the actions resulting from this approach (cooling needs reductions, controls
VFDs, etc.) can be evaluated as separate investments. However, it is important to keep
the whole picture in mind to assure that the economic benefits are optimized over the
entire system. The economic benefits have to be evaluated over the entire life time.
In general, the investment for hybrid cooling systems is significantly larger than for dry
coolers, but the water cost are lower (see Figure 34)
Additional cost for hybrid cooling tower versus water saving:
Figure 34. Cost comparison between hybrid cooling towers and conventional wet cooling
systems. The comparison is based on a cooling load of 2 030 KW, an inlet temperature
of 40°C, an outlet temperature of 30°C and a wet bulb temperature of 274°C
(Seneviratne M., 2007 ; based on data of Baltimore Aircoil)
Driving force for implementation
The main driving forces for implementation are:
- Energy savings;
- Water savings, especially under the climatic conditions in south of Europe;
The climatic conditions in south of Europe will lead to alternative selection of
technologies.
- Water scarcity in south of Europe;
- Cost savings.
Reference organizations
BOSCH (http://www.bosch.com/en/com/home/index.php) In the Bosch metal cutting
departments in Feuerbach and Bamberg the systematic approach resulted in a total
savings of 4 000 MWh per year (Energiewende180, 2015).
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December 2015 160
Volkswagen is an automobile manufacture. (http://en.volkswagen.com/en.html). In its
plant in Salzgitter VFD drives are installed (Grundfos, 2015).
Reference literature Baltimore Aircoil, 2015, Closed circuit cooling towers, Technical note, available online at:
http://www.baltimoreaircoil.eu/sites/BAC/files/BAC_Tab_ClosedCircuitCoolingTowers_EN
v00_0.pdf, last accessed on 28th September 2015.
Baltimore Aircoil, 2015, HXI Closed circuit cooling towers. Principle of operation,
Technical note, available online at:
http://www.baltimoreaircoil.eu/node/8423, last accessed on 28th September 2015.
Baltimore Aircoil, 2015, Adiabatic cooling, available online at:
http://www.building.co.uk/adiabatic-advances/3114560.article, last accessed on 28th
September 2015.
Cooling Technology Institute, 2008, Guideline: Best Practices for Control of Legionella,
available online at:
http://www.cti.org/downloads/WTP-148.pdf, last accessed on 28th September 2015.
Energiewende 180, 2015, available online at:
http://www.energiewende180.de/en/projects/project-single/article/kuehlschmierstoffe-
bei-der-metallzerspanung-energieeffizient-einsetzen/, last accessed on 5th June 2015.
Grundfos, 2015, Speed controlled pumps save energy at Volkswagen, available online
at:
http://machining.grundfos.de/the-knowledge-link/industry-news/speed-controlled-
pumps-save-energy-at-volkswagen, last accessed on 5th June 2015.
Heemer J., Mitrovic A., Scheer M., 2011, Increasing central plant efficiency via a water
to water heat pump, Pharmaceutical engineering, May/June 2011, Vol 31 No 3, available
online at:
http://www.johnsoncontrols.com/content/dam/WWW/jci/be/integrated_hvac_systems/h
vac_equipment/chiller_products/water-heat-
pump/WTWHP_article_from_May_2011_Pharmaceutical_Engineering_mag.pdf, last
accessed on 5th June 2015.
Seattle Public Utilities, 2015, Cool tunes, Run an efficient cooling tower, available online
at:
http://www.savingwater.org/cs/groups/public/@spu/@swp/documents/webcontent/04_0
09226.pdf, last accessed on 5th June 2015.
Seneviratne M., 2007, A Practical Approach to Water Conservation for Commercial and
Industrial Facilities, 1st Edition. Elsevier Science, 400p, available online at:
http://www.energyefficiencyasia.org/docs/ee_modules/Chapter-Cooling%20Towers.pdf,
last accessed on 5th June 2015.
US Department of Energy, 2011, Cooling Towers: Understanding Key Components of
Cooling Towers and How to Improve Water Efficiency, available online at:
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 161
http://www1.eere.energy.gov/femp/pdfs/waterfs_coolingtowers.pdf, last accessed on
28th September 2015.
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December 2015 162
2.2.9. Efficient use of compressed air systems
Description
Compressed air is a very convenient energy carrier that is widely used in the metal
fabrication sector for hand tools, instrumentation, processes, etc. Nevertheless, it is
often not the optimal solution in terms of energy efficiency and total cost of ownership.
Typically, only 17% of the total energy supplied to the compressor is converted into
usable energy (Radgen, website). Compressed air systems often seem interesting
because of a low initial investment cost. However, their energy consumption is
responsible for 75% of the total lifetime costs.
To optimize the use of compressed air, it is important to take the following elements into
account:
1) Elimination of inappropriate use of compressed air;
2) Optimization of the compressed air system configuration;
3) Optimization of the compressed air use;
4) Appropriate maintenance for compressed air systems.
Companies can optimize the use of compressed air based on these elements, in order of
enumeration, but might also choose a different starting point.
Elimination of inappropriate use of compressed air
Inappropriate use of compressed air refers to all applications which can be executed in a
more effective or efficient manner without the use of compressed air.
Table 19 provides some examples of inappropriate use of compressed air and suggests
alternative methods. Especially the low-pressure uses (EREE, 2004) of compressed air
should be looked at carefully. Depending on the application and specific context,
compressed air can be the preferred option despite its higher environmental impact:
- It can be used where other energy types cannot be used due to explosion hazard,
fire risk or extreme temperatures;
- It can be executed with a high degree of cleanliness, where quality, hygiene and
safety are essential;
- Pneumatic tools are often much lighter than the equivalent electrical models,
making them easier for an operator to handle;
- Pneumatic tools usually wear out slower and more gradually compared to for
example electric tools.
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Table 19. Overview of the most common types of inappropriate use of compressed air in the Fabricated Metal Products Sector
Potentially
inappropriate uses
Examples within the
Fabricated Metal Products
sector
Suggested
alternatives/
actions
Remarks
Open blowing,
mixing, drying,
cooling,
atomizing,
padding, etc.
Cleaning of machines or
finished parts, cooling after
heat treatment, drying after
wet process steps,
airbrushes, paint sprayers, air
gages, aerating/agitating
equipment, cooling in welding
equipment, etc.
Fans, blower,
mixers, nozzles
Open-blowing applications waste compressed air. For existing
open-blowing applications, high efficiency nozzles could be
applied, or if high-pressure air isn’t needed, consider a
blower or a fan. Mechanical methods of mixing typically use
less energy than compressed air.
Parts cleaning and
sparring
Cleaning burrs, turnings,
sandblasting, etc.
Brushes, blowers,
vacuum pumps
Low-pressure blowers, electric fans, brooms, and high-
efficiency nozzles are more efficient for parts cleaning than
using compressed air to accomplish such tasks.
Vacuum generator Vacuum based tools used for
material handling,
automation, vacuum
clamping fixtures and jigs,
etc.
Dedicated vacuum
pump or central
vacuum system
Air motors and air
pumps
Pneumatic grinders, ratchets,
jacks, drills, hammers,
riveters, etc.
Electric motors,
mechanical pumps
The tasks performed by air motors can usually be done more
efficiently by an electric motor. Similarly, mechanical pumps
are more efficient than air-operated double diaphragm
pumps. However, in hazardous environments (e.g. explosive
atmospheres) compressed air might be an appropriate and
safe choice. If air motors and pumps are used, proper
regulator and speed control are needed
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Potentially
inappropriate uses
Examples within the
Fabricated Metal Products
sector
Suggested
alternatives/
actions
Remarks
Idle equipment Put an air-stop
valve at the
compressed air inlet
Equipment that is temporarily not in use during the
production cycle.
Abandoned
equipment
Disconnect air
supply to
equipment
Equipment that is no longer in use either due to a process
change or malfunction.
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Optimization of the compressed air system configuration
The right set-up and configuration of a compressed air system can lead to important
cost and environmental impact savings. This is valid for greenfield projects, as well as
for existing plants. Table 20 gives an overview of some basic considerations for the
design of a performant compressed air system.
Table 20. Overview of the main measures related to compressed air system
configuration
Action Description
Use compressors with
variable speed drives
Most air compressors become less energy efficient as air
demand is reduced. In extreme cases, up to 65% of the rated
electrical power is still used even when there is no demand
for air. By purchasing a variable speed drive (VSD)
compressor (Carbon Trust, 2012) or retrofitting a VSD to an
existing compressor companies can save energy and money.
Optimal control of the
compressed air system
System control can consist of using simple isolated
controls, such as:
• Time-operated valves that control different ‘zones’ of the
compressed air circuit;
• Interlocks that allow the compressed air circuit to open only
when a particular air-using machine is running;
• Sensors that detect when a product is present and then
open the compressed air circuit.
These controls could be integrated within a building
management system or a plant/process control system.
Alarms can be set that indicate plant faults or when threshold
limits have been reached.
Controlling multiple
compressors
Where cascade pressure control is often used in industry, a
more efficient method of controlling multiple compressors is
via an electronic sequential controller, which can control
multiple compressors around a single set pressure. These
systems also make compressors available to match demand
as closely as possible. This control can also predict when to
start/stop or load/unload the next compressor in sequence by
monitoring the decay/rise in system pressure. They can also
be set to vary the pressure according to production
requirements, for example, lower pressure at weekends.
Stabilizing system
pressure
Stabilizing system pressure (EERE , 2004) is an important
way to lower energy costs and maintain reliable production
and product quality. Three methods can be used to stabilize
system pressure: (1) adequate primary and secondary
storage; (2) Pressure/Flow Controllers (P/FCs); (3) use of
dedicated compressors.
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Action Description
Choosing the right air
quality
Higher quality air requires additional air treatment
equipment, which increases capital costs as well as energy
consumption and maintenance needs (EERE, 2004). The
quality of air produced should be guided by the degree of
dryness and filtration needed and by the minimum acceptable
contaminant level to the end uses. One of the main is
whether lubricant-free air is required. Lubricant-free air can
be produced either by using lubricant-free compressors, or
with lubricant-injected compressors and additional air
treatment equipment.
Effect of intake on
compressor
performance
Contaminated or hot intake air can impair compressor
performance and result in excess energy and maintenance
costs (EERE, 2004). The location of the entry to the inlet pipe
should be as free as possible from ambient contaminants
(e.g. rain, dirt, discharge from a cooling tower), and inlet
temperature should be kept to a minimum. The inlet pipe size
must be large enough to prevent pressure drop and reduction
of mass flow. All intake air should be adequately filtered.
Consider heat recovery About 80 to 90% of the electrical input to a compressor is lost
as heat. Recovery of waste heat from air and water cooled
compressors can reduce energy use for heating and save
money. Heat recovery systems (Carbon Trust, 2012;
Moskowitz , 2010) are particularly beneficial for sites with
demands for hot water or heating, including water, space or
process heating, drying.
Select the right type of
compressor technology
Basically 3 types of compressors exist: reciprocating, rotary
and centrifugal compressors. Depending on the application
(required pressure, volume, variability, etc.) one technology
may prove more energy efficient and controllable than the
other on a particular duty, and maintenance costs between
the different technologies can vary considerably. Therefore,
when selecting an air compressor, it is important to look at
the total cost across the system, over the life cycle of the
equipment.
Optimization of the compressed air use
Where compressed air is the energy carrier of choice, choosing an optimal use and
control (basic parameters, such as the pressure set point) can save costs and
environmental impacts. Table 21 gives a set of steps that can guide users to optimize
their compressed air use (EERE, 2004).
Table 21. Sequence of steps that can be used to optimize the settings of compressed
air systems
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Step Action
1 Review the pressure level requirements of the end-use applications. Those
pressure level requirements should determine the system pressure level.
Because there is often a substantial difference in air consumption and pressure
levels required by similar tools available from different manufacturers, request
exact figures from each manufacturer for the specific application. Do not
confuse maximum allowable with required pressure.
2 Monitor the air pressure at the inlet to the tool. Improperly-sized hoses, fittings
and quick disconnects often result in large pressure drops. These drops require
higher system pressures to compensate, thus wasting energy. Reduced inlet
pressure at the tool reduces the output from the tool and, in some cases, may
require a larger tool for the specified speed and torque.
3 Avoid the operation of any air tool at “free speed” with no load. Operating a
tool this way will consume more air than a tool that has the load applied.
4 End uses having similar air requirements of pressure and air quality may be
grouped in reasonably close proximity, allowing a minimum of distribution
piping, air treatment, and controls.
5 Investigate and, if possible, reduce the highest point-of-use pressure
requirements. Then, adjust the system pressure.
Appropriate maintenance for compressed air systems
Like for most energy using equipment, proper maintenance is paramount to assure
reliable and energy-efficient performance. Table 22 lists the main types of
maintenance actions (EERE, 2004).
Table 22. Considerations for optimal maintenance of compressed air systems
Action Description
Leak reduction All compressed air systems have leaks, even new ones. A
continuous effort to reduce air leaks will lead to important
energy savings. The sources of leakage are numerous, but the
most frequent causes are: manual condensate drain valves left
open; failed auto drain valves; shut-off valves left open;
leaking hoses and couplings; leaking pipes, flanges and pipe
joints; strained flexible hoses; leaking pressure regulators; air-
using equipment left in operation when not needed. Besides
listening and using a soapy water solution, ultrasonic leak
detection equipment can be used. Routinely check compressed
air systems for leaks.
Implementation of
preventive
maintenance plan
Like all electro-mechanical equipment, industrial compressed
air systems require periodic maintenance to operate at peak
efficiency and minimize unscheduled downtime. Inadequate
maintenance can increase energy consumption via lower
compression efficiency, air leakage, or pressure variability. It
also can lead to high operating temperatures, poor moisture
control, excessive contamination, and unsafe working
environments. Some very handy templates for maintenance
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Action Description
plans and checklist are available.
Appropriate removal
of condensate
Removing condensate (EERE, 2004) is important for
maintaining the appropriate air quality level required by end
uses. However, significant compressed air (and energy) losses
can occur if condensate removal is done improperly. Drain the
condensate often and in smaller quantities rather than less
frequently and in larger quantities. Consider oversized
condensate treatment equipment to handle unexpected
lubricant loading and to reduce maintenance. Consider using
zero loss drain traps.
Replace tools in time Check the useful life of each end-use application. A worn tool
will often require higher pressure and consume excess
compressed air.
Lubricate properly Air tools should be lubricated as specified by the manufacturer.
Achieved environmental benefits
Compressed air is used in various processes and applications. Between 10 and 30% of
the energy consumption of a manufacturing plant in the Fabricated Metal Products
sector can be attributed to compressed air (Energie Agentur, 2015). Compressed air is
a convenient, easy and safe energy carrier for a lot of processes and applications.
For industrial tools and machines, the use phase accounts typically between 80 and
95% of the total life cycle impact. The energy consumption of these tools and
machines is consequently a dominant factor in the total environmental impact, that
generally outweighs other life cycle stages like production of the equipment, logistics
and end-of-life. Typically only 17% of the total energy supplied to the compressor is
converted into usable energy. Electric tools generally only need 10 to 30% of the
energy that pneumatic tools use for the same operation. Therefore, compressed air is
not always the best choice in terms of environmental impact.
Depending on the application and specific context, compressed air can be the
preferred choice despite its higher environmental impact, because
- It can be used where other energy types cannot be used due to explosion
hazard or fire risk;
- It can be executed with a high degree of cleanliness, where quality, hygiene
and safety are essential;
- Air tools are often much lighter than the equivalent electrical models, making
them easier for an operator to handle (website LCA2Go).
Table 19 gives and overview of some possible inappropriate uses of compressed air.
An electrically powered angle grinder typically uses about 540 to 900 W. by using a
compressed air-powered equivalent the consumption will be about 3.5 kW. In this
example, compressed air is not useful and should be eliminated if possible (Stanley
Assembly Technologies, 2001).
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Not only the selection of another energy carrier, but also the optimization of the
configuration, use and maintenance of compressed air systems can lead to
considerable cost and energy savings. The potential of energy savings evidently
depends on the current use and performance of the compressed air systems. Savings
of 40% and more are regularly reported in industrial companies, attained without
large investments (Table 23).
Because of the specific context of each manufacturing plant, the starting position and
the multitude of possible actions, it is difficult to estimate or project the potential
overall savings in environmental impacts in general. Table 23 and Figure 35 give some
indications and examples of the potential savings related to optimized use of
compressed air.
Table 23. Examples of achievable energy saving through compressed air measures in
an industrial context (Carbon Trust, 2012)
Action Potential Energy saving
Reduce the average air intake
temperature
A reduction of the air intake temperature with
4°C leads to a 1% energy saving.
Leak reduction Eliminating a leak of 1 mm² in a compressed
air system operating at 6 bar leads to an
energy saving of 15 MWh per year.
Optimization of the usage regime of
compressed air systems
Even when idling, compressors can consume
between 20-70% of their full load power.
Reduce the pressure of the
compressed air system to the minimal
pressure required
For a typical screw compressor operating at
7 bar, every reduction of the pressure with
0.5 bar will lead to an energy saving of 3-
4%.
Waste energy recovery Up to 80% of the energy used in compressing
air can be used, for example in low-grade
space heating, conversion into hot water or
preheating boiler water. Waste recovery in
general requires some investments.
Optimized maintenance Tests carried out on over 300 typical
compressors show that energy savings of
10% can be achieved through low-cost
maintenance activities. So, in addition to
improving reliability, maintenance can also
save energy and money.
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Figure 35: Potential saving related to compressed air (Ceati, 2007)
Appropriate environmental indicators
The energy consumption during the use phase is a predominant factor in the total life
cycle environmental impact of tools and machines, accounting for typically 80% and
more. The energy use per output is consequently a good indicator of the overall
environmental performance of tools and machines. Depending on the specific context,
this can be expressed in terms of kWh/kg, kWh per number of produced parts, etc.
This indicator can be used for tools and machines using whatever energy carrier
(compressed air, electric) (Marshall, 2013). More easy to measure is the installed
power for compressed air.
For compressed air tools and machines, the conversion factor can be calculated
relating the used flow of compressed air with the total electricity consumption needed
to power the compressors.
To follow up the environmental performance of the compressed air tools and machines
specifically (and monitor their efficiency and operational performance), an additional
set of indicators can be used. These are rather of a technical nature, but give a good
insight of the environmental performance of the compressed air system. These
indicators include:
- Pressure of the compressed air system(s) in bar;
- Compressed air production equipment power consumption (per system) in
kWh, per day, per month, per year, etc.
- Compressed air flow (per system, division, etc.) in standard cubic meter per
minute.
Cross-media effects
The measures related to optimization of the configuration, use and maintenance of
compressed air systems usually have no negative effects on other environmental
compartments. In the case of large investments (improved compressor technology,
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alternative energy carrier), there is an environmental impact related to the production
and end-of-life of the tools and machines.
When compressed air tools are replaced (where and when feasible) by pneumatic tools
using batteries, this can lead to high battery and WEEE waste streams. In case they
are replaced by tools using electricity this will not give an negative impact.
As explained above, the improved energy efficiency in the utilization of the tools and
machines usually outweigh these impacts.
Operational data
In the Fabricated Metal Products sector a wide range of compressed air tools and
machines is used, and this in a wide variety of processes, circumstances,
requirements, etc. On the other hand, this BEMP describes a broad set of measures
and actions on different levels:
- Elimination of inappropriate use of compressed air;
- Optimization of the compressed air system configuration;
- Optimization of the compressed air use;
- Appropriate maintenance for compressed air systems.
That makes it impossible to describe exhaustively the operational data of all these
measures. In the first instance, it is very important that companies start to measure
and monitor the important parameters and indicators related to the use of compressed
air, on the level of their plant, division, compressor, compressor system, machine or
type of machine, etc. This helps to build up knowledge and insight in the actual
performance of the compressed air system, the effectiveness of measures, the
procedures, the behaviour of users, etc. Combine this with a sustained attention for
the performance of the compressed air system, it becomes possible to follow up and
improve its performance and to implement this BEMP.
Bombardier (a producer of trains) reduced its compressed air consumption by a
quarter. The same company did flow measurements to map its consumption profile. As
the demand for compressed air lowered, it could replace big compressors by smaller,
more efficient ones (Encon, 2015).
Applicability
The design (configuration), operation and maintenance of compressed air systems can
be optimized in every Fabricated Metal Products company. Of course, the energy
saving potential depends largely on the plant specificity and its current situation. The
optimized configuration and use of compressed air systems requires some specific
knowledge. Ideally, the compressed air use is followed up by an employee with the
necessary skills. Of course, activities related to the design and maintenance can also
be outsourced to the equipment supplier or a maintenance company.
Economics
Many of the described energy saving measures for compressed air systems can be
done without large investments, and often have a reasonably short payback period
(DoE reported a median payback period of 18 months for measures other than
compressor changes). Only for more drastic changes (e.g. implementation of other
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technologies instead of compressed air, replacement of a compressor) investment may
be higher and payback period may be longer. These changes may be easier to
implement at tipping points like replacement of old equipment, plant extensions or
modifications, etc.
Driving force for implementation
The environmental performance of compressed air systems, tools and machines in the
sector is largely dominated by their energy consumption, which is directly linked to
energy costs. Consequently, both economic and environmental drivers are applicable
at the same time: companies will consider applying this BEMP because of
environmental concerns and/or cost drivers.
Related to the elimination of inappropriate use of compressed air, it is known that also
other aspects and drivers can play a role, such as compatibility with explosion and fire
hazards, cleanliness and hygiene requirements, ergonomics, ease of maintenance and
durability.
Reference organizations
Alutec: manufacturer of alloy wheels (Accessory Division) and wheels suppliers to the
automotive industry (Automotive Division).
Volvo Cars: is a truck and car producer. In their production plan in Ghent, Volvo
reviewed the compressed air system (Volvo, 2012).
Reference literature
Carbon Trust, 2012, How to utilise variable speed drives with air compressors –
technical note, available online at:
http://www.carbontrust.com/media/147017/ctl167_variable_speed_motor_driven_air
_compressors.pdf, last accessed on 11th June 2015.
Carbon Trust, 2012, How to recover heat from a compressed air system – technical
note, available online at:
http://www.carbontrust.com/media/147009/j7967_ctl166_how_to_recover_heat_from
_a_compressed_air_system_aw.pd, last accessed on 11th June 2015.
Carbon Trust, 2012, Compressed air, Opportunities for businesses, available online at:
http://www.carbontrust.com/media/20267/ctv050_compressed_air.pdf, last accessed
on 11th June 2015.
Ceati, 2007, Compressed Air Energy Efficiency reference guide, available online at:
http://www.ceati.com/freepublications/7017A_guide_web.pdf, last accessed on 11th
June 2015.
EERE Information Centre, 2004, Eliminate Inappropriate Uses of Compressed Air,
Energy Tips Compressed Air (#2). Aug. 2004, available online at:
http://www.compressedairchallenge.org/library/tipsheets/tipsheet02.pdf, last
accessed on 11th June 2015.
EERE Information Centre, 2004, Determining the right air quality for your compressed
air system, Energy Tips Compressed Air (#5). Aug. 2004, available online at:
Background document on best environmental management practice in the Fabricated Metal Products sector
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http://www.compressedairchallenge.org/library/tipsheets/tipsheet05.pdf, last
accessed on 11th June 2015.
EERE Information Centre, 2004, Remove condensate with minimal air loss, Energy
Tips Compressed Air (#6). Aug. 2004, available online at:
http://www.compressedairchallenge.org/library/tipsheets/tipsheet06.pdf, last
accessed on 11th June 2015.
EERE Information Centre, 2004, Stabilizing System Pressure, Energy Tips Compressed
Air (#8). Aug. 2004, available online at:
http://www.compressedairchallenge.org/library/tipsheets/tipsheet08.pdf, last
accessed on 11th June 2015.
EERE Information Centre, 2004, Engineer End Uses for Maximum Efficiency, Energy
Tips Compressed Air (#10). Aug. 2004, available online at:
http://www.compressedairchallenge.org/library/tipsheets/tipsheet10.pdf, last
accessed on 11th June 2015.
EERE Information Centre, 2004, Remove condensate with minimal air loss, Energy
Tips Compressed Air (#13). Aug. 2004, available online at:
http://www.compressedairchallenge.org/library/tipsheets/tipsheet13.pdf, last
accessed on 11th June 2015.
EERE Information Centre, 2004, Effect of intake on compressor performance, Energy
Tips Compressed Air (#14). Aug. 2004, available online at:
http://www.compressedairchallenge.org/library/tipsheets/tipsheet14.pdf, last
accessed on 11th June 2015.
Encon, 2015, Encon analyses and optimises compressed air consumption
http://www.encon.be/en/our-clients-case-studies-detail.aspx?ID=4f16a067-7f05-
4fdc-9d00-0bc3ea2cbe14, last accessed on 17th August 2015.
EnergieAgentur NRW, 2015, Online publication “Energieeffizienz in Unternehmen” ,
2015, available online at:
http://www.energieagentur.nrw.de/unternehmen/energieeffizienz-in-der-eisen-und-
metallwarenindustrie-3748.asp, last accessed on 17th August 2015.
Gonzalez, A., 2007, Master Thesis “Machine Tool Utilisation Phase: Costs and
Environmental Impacts with a Life Cycle View”
LCA2Go, 2015, Webpage of the FP7 project LCA-to-go for the target group of
industrial machines, with several case studies with total life cycle impacts of machines
and tools, available online at:
http://www.lca2go.eu/sectors,tooling.en.html, last accessed on 17th August 2015.
Marshall, R., 2013, Using KMI’s for peak efficiency, Compressed Air Challenge, July,
2013, available online at:
https://www.compressedairchallenge.org/library/articles/2013-07-CABP.pdf, last
accessed on 17th August 2015.
Moskowitz, F., 2010, Heat Recovery and Compressed Air Systems. Compressed Air
Challenge, Sept, 2010, available online at:
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December 2015 174
http://www.compressedairchallenge.org/library/articles/2010-09-CABP.pdf, last
accessed on 17th August 2015.
Radgen, P., The .Efficient Compressed Air. Campaign in Germany . Market
transformation to activate cost reductions and emissions savings, available online at:
http://www.pius-info.de/files/druckluft_aceee-paper.pdf, last accessed on 17th August
2015.
Stanley Assembly Technologies, 2001, Fastening technology energy consumption of
pneumatic and DC electric assembly tools. May 2001, 6p, available online at:
http://www.toolsmith.ws/catalogs/Stanley%20Assembly%20Tools/Energy%20Consum
ption.pdf, last accessed on 17th August 2015.
Volvo, 2012, Volvo Europa truck NV, First CO2-free company in Belgium and the first
CO2 -free automotive factory worldwide, available online at:
http://www.volvotrucks.com/SiteCollectionDocuments/VTC/Corporate/About%20us/En
vironment-2012/CO2_gent_eng.pdf, last accessed on 17th August 2015.
U.S. Department of Energy , 2004, Evaluation of the Compressed Air Challenge®
Training Industrial Technologies Program.
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2.2.10. Reduction of standby energy of metal working machines
Description
The energy consumption during standby modes often represents a significant share of
the total energy demand of manufacturing processes (Duflou et al, 2011). Coolant
circulation, compressed air, auxiliary components such as electronics and fans
consume up to 30% of the energy use during standby (Kellens et al, 2013). These
processes are required to insure machine readiness, data transfers and to avoid long
warm up periods (see Table 24)Error! Reference source not found.. During
standby mode, the machine does not produce value and thus the amount of used
energy can be reduced as much as possible.
Table 24. Overview of auxiliary processes during standby mode (Duflou et al., 2011)
As energy represents power consumption over a certain time period, the standby
energy can be reduced by lowering the standby power demand, as well as limiting the
duration of standby activities. While the first can be obtained by selectively switching
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off non-required subunits, the latter can be achieved by optimized production
planning. Examples can be found in increasing the machine tool utilization, as well as
(temporary) switching off non-required machine tools.
For each machine individually, a guidance list should be built indicating which
components/functions need to be turned off at which specific moments. Afterwards,
this can be programmed in a CNC controller accordingly. Some questions that need to
be addressed are: What components to switch of after for an hour of inactivity? What
component for a night/shift of inactivity? For a week-end? etc. The CNC controller can
give an indication to the operator to switch off components or the latter can be done
automatically.
A good example can be seen in Error! Reference source not found., where in the
CNC controller functions are built in to allow the machine operators to shut down non-
essential function and/or to automatically active them before the shift starts. This
insures the operator to start working with a warm machine, without leaving the
machine using unnecessary energy during the night/weekend.
Figure 36: Energy management in a CNC controller (Heidenhain, 2010)
Achieved environmental benefits
A large reduction of energy consumption can be achieved by shutting down non-
essential functions during standby of a machine. In addition, pumps, electrical servo
engines and other electrical components which remain active during standby are
subject to wear and aging. Selectively shutting them down can therefore greatly
increase their lifetime, reduce maintenance cost and lower the amount of spare parts
needed in stock.
Appropriate environmental indicators
An appropriate environmental indicator is the amount of energy used per produced
unit (kWh machine power per batch).
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Cross media effects
In many electrical equipment the energy peak during start up is rather large and can
cause aging than in the case where machines are turn off. The latter results in higher
power needs and/or early part replacement. In particular the circuit boards used for
the NC controllers are vulnerable for peak loads. In addition, EDM generators and
laser sources also suffer from cyclic loads, resulting in the common practice to not
shut down production machines between jobs unless longer downtimes are expected.
However, consistent switch-off of auxiliary components (hydraulics, spindle cooling) or
the compressed-air supply can also have the opposite effect. If the sudden removal of
waste heat from auxiliary components or of the temperature-stabilizing effect of media
causes thermal displacement in the machine frame, it can result in scrap parts, which
impair the energy balance of a production process. The selective switch-off of auxiliary
components therefore functions best for machines with little inclination to thermal
displacement. In any case, careful planning of the energy saving effects is a
prerequisite (Heidenhain, 2010).
Operational data
Metal working machines, such as lathes, milling machines, EDM and/or hybrid
processes all consume a large amount of energy during their machining processes.
Figure 37Error! Reference source not found. depicts the energy consumed by a
rough and finishing milling operation of a rectangular aluminium housing.
Figure 37: Power requirement for roughing (top) and finishing (bottom) milling of the
housing (Heidenhain, 2010)
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As can be seen the external processes, such as cooling fluid and compressed air take
up a large part of the power requirement, while auxiliary components of the machine
and spindle follow. The power use during production (green bar in Figure 38 left side)
is scarcely higher than during standby (blue bar in Figure 38Error! Reference source
not found. left side). The consumption of compressed air and lubricants are mostly
automatically shut down or minimized when the machine is in between operations, the
auxiliary components general remain active. These auxiliary components consist of the
CNC system, lights, axis cooling systems and electronics.
Figure 38: Machine power requirement
Kellens et al. (2013) show that for a CO2 cutting laser the standby energy can be
reduced considerably by introducing power saving modules in the controller (Figure
39)Error! Reference source not found.. These achieved energy savings de-activate
the non-essential subunits and insure quick reactivation when the machine needs to
operate, resulting in a reduction up to 66% of standby power requirement. Fanuc (the
producer of the equipment) has implemented these savings on their latest controllers,
allowing operators and engineers to optimize energy use without hindering production.
Figure 39: Energy profile for a CO2 laser (Kellens et al. 2013)
Therefore machine operators can greatly reduce the overall machine power
consumption by selectively shutting down non-essential machine activities when they
work on standby mode.
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Applicability
The technique is applicable in all up to date CNC controlled machine. The use of
controlling software can be updated with suitable routines (programs) having the
above mentioned setting possibilities.
In older machines, without the software control options, manual interventions have to
be made in the hardware, which is often undesirable due to lack of flexibility and the
added cost (usually the settings are lost and thus extra time is needed).
Table 25. Energy savings for several machines, comparison standby and shut down
(Kellens et al., 2013)
In Table 33Error! Reference source not found. a comparison is made between
either shutting down a machine, and having it reside in standby mode. The cost for
shutting down and staying idle for 30 min are compared and it can be seen that for
certain machines (Struder S40 and DMU 60P) idling has a significant impact on the
energy consumption. Based upon these calculations, a correct shut down procedure
can be developed, allowing rapid responses to production demands and improved
energy use.
Economics
Figure 37Error! Reference source not found. illustrates machine standby power
requirements, which range from 5 to 15 kW. Depending on the working regime
(24h/24h or only day shift) the benefits can be significant if only a reduction of 2 to 3
kW is achieved, considering an electricity cost of 50-60 euro MWh (estimate based on
average industrial end user power price, 2014). In addition, the lower rate of aging of
equipment significantly lowers the amount of maintenance interventions required,
driving down cost of ownership considerably.
Driving force for implementation
The driving force for implementation is the cost of energy and spare parts.
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Reference organisations
Volvo Cars - productions of cars and trucks.
In their production plan in Ghent, they shorten the stand-by time of hydraulic groups
(Volvo, 2012)
Reference literature Duflou, J., Kellens, K., Renaldi, Dewulf, W., 2011, Environmental performance of sheet
metal working processes, Key Engineering Materials 473, p. 21.
Heidenhain, 2010, Aspects of Energy Efficiency in Machine Tools, available online at:
http://www.heidenhain.de/fileadmin/pdb/media/img/Energieeffizienz_WZM_en.pdf,
last accessed on 28th September 2015.
Kellens K., Dewulf W., Lauwers B , Krutha J-P, Duflou J.R., 2013, Environmental
Impact Reduction in Discrete Manufacturing: Examples for Non-Conventional
Processes. The Seventeenth CIRP Conference on Electro Physical and Chemical
Machining (ISEM). Procedia CIRP 6 (2013) 27 – 34.
Kellens K., 2013, Energy and resource efficient manufacturing, unit process analysis
and optimization, thesis, available online at:
https://lirias.kuleuven.be/bitstream/123456789/425178/1/PhD_Thesis_KellensKarel_E
nergy+and+Resource+Efficient+Manufacturing.pdf, last accessed on 9th October 2015
Volvo, 2012, Volvo Europa truck NV, First CO2-free company in Belgium and the first
CO2 -free automotive factory worldwide, available online at:
http://www.volvotrucks.com/SiteCollectionDocuments/VTC/Corporate/About%20us/En
vironment-2012/CO2_gent_eng.pdf, last accessed on 28th September 2015.
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2.3. Best environmental management practices for the manufacturing
processes
The proposed BEMPs for the manufacturing processes are split up in BEMPs for all
manufacturing processes:
2.3.1 Application of solid low-friction coatings on tools and components;
2.3.2 Application of wear- and corrosion-resistant coatings of tools and
equipment;
2.3.3 Selection of coolant as environmental and performance criterion
BEMPs for forming processes:
2.3.4 Incremental Sheet metal Forming (ISF) as alternative for mould making;
2.3.5 Additive manufacturing of complex equipment - flow optimization for
optimal heat transfer and temperature control;
2.3.6 Multi-directional forging: a resource efficient metal forming alternative.
BEMPs for removing processes:
2.3.7 Hybrid machining as a method to reduce energy consumption
2.3.8 Machining of near-net-shape feedstock.
and BEMPs for finishing processes:
2.3.9 Reduce the energy for paint booth HVAC with predictive control;
2.3.10 Selection and optimization of thermal processes for curing wet-chemical
coatings on metal products.
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2.3.1. Application of solid low-friction coatings on tools and components
Description
In the Fabricated Metal Products sector lubricants are widely used for a variety of
applications, e.g. for reducing friction, protecting them against wear and keeping
moving surfaces clean and cool. Lubricants have to be replaced and disposed of after a
certain time. In order to avoid, or if not feasible, lower the use of liquid lubricants,
solid low-friction coatings can be applied. These solid low-friction coatings will lower
wear and make it possible to lubricate closed or unreachable (space) systems for
extended time. The advantages and disadvantages of applying solid low-friction
coatings are listed in Table 26.
Table 26. Advantages and disadvantages of applying solid low-friction coatings
Advantages Disadvantages
- Are highly stable in high-
temperature, cryogenic, vacuum
and high-pressure environments
- Have higher coefficients of friction and
wear than for hydrodynamic lubrication
- Have high heat dissipation with high
thermally conductive lubricants,
such as diamond films
- Have poor heat dissipation with low
thermally conductive lubricants, such as
polymer-based films
- Have high resistance to
deterioration in high-radiation
environments
- Have poor self-healing properties so that
a broken solid film tends to shorten the
useful life of the lubricant
- Have high resistance to abrasion in
high-dust environments
- May have undesirable colour, such as
with graphite and carbon nanotubes
- Have high resistance to
deterioration in reactive
environments
- Are more effective than fluid
lubricants at intermittent loading,
high loads, and high speeds
- Enable equipment to be lighter and
simpler because lubrication
distribution systems and seals are
not required
- Offer a distinct advantage in
locations where access for servicing
is difficult
- Can provide translucent or
transparent coatings, such as
diamond and diamond-like carbon
films, where desirable
A whole range of solid lubricant films are listed below:
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- Nanotubes, nano-onions, and other nanoparticles (C, BN, MoS2, and WS2);
- Nanocomposite coatings (WC/C, MoS2/C, WS2/C, TiC/C, and nanodiamond);
- Diamond and diamond-like carbon coatings (diamond, hydrogenated carbon (a-
C:H), amorphous carbon (a-C), carbon nitride (C3N4), and boron nitride (BN)
films);
- Superhard or hard coatings (VC, B4C, Al2O3, SiC, Si3O4, TiC, TiN, TiCN, AlN, and
BN);
- Lamellar film (MoS2 and graphite);
- Non-metallic film (titanium dioxide, calcium fluoride, glasses, lead oxide, zinc
oxide, and tin oxide);
- Soft metallic film (lead, gold, silver, indium, copper, and zinc);
- Self-lubricating composites (nanotubes, polymer, metal-lamellar solid, carbon,
graphite, ceramic, and cermets);
- Lamellar carbon compound film (fluorinated graphite and graphite fluoride);
- Carbon;
- Polymers (PTFE, nylon, and polyethylene);
- Ceramics and cermets.
Figure 40 illustrates comparison of different solid lubricants in friction coefficient and
lifetime.
Figure 40. Comparison of frictional performance; BALINIT is a solid low-friction coating
(Oerlikon Balzers, 2010)
Figure 41 presents a comparison of the life time for a lab test with different types of
lubrication. Important to note is that depending on the type of contact and the type of
load, different systems of solid lubricants can be the most beneficial. An example is
the comparison between MoS2 and DLC (Diamond Like Carbon). In particular, MoS2
friction degrades in humid atmosphere, but is excellent in vacuum or low humidity,
while for DLC, the opposite is true. Some of the solid lubricant coatings have a
temperature limit or cannot be used in certain processes like food or medical, because
of toxicity). Figure 41 illustrates that coating (dry use) can increase the number of
cycle times with a factor 100.
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Figure 41. Solid low-friction coating (BALINIT C) in dry running and starved lubrication
(gear test) (Oerlikon Balzers, 2010)
The techniques to apply the solid low-friction coatings, depending on the application,
are i. vacuum technology like PVD and CVD, ii. (thermal) spraying and iii. flow coating.
Achieved environmental benefits
The application of solid low-friction coatings leads to limited or no use of liquid
lubricants, resulting in lower disposal of lubricants. The induced higher life time of
tools and equipment leads to less scrap production and less material use to make new
products.
More optimal processes and energy use can be achieved as well, e.g. faster
processing, more consistent process speed and less interruption.
Furthermore, the application of solid low-friction coatings requires no liquid grease so
operators are no longer exposed to (toxic) additives, VOCs, etc., resulting in healthier
and cleaner work environment.
Appropriate environmental indicators
Appropriate environmental indicators are listed below:
- Amount of waste linked to the lubricants use: kg waste for disposal per year;
kg waste for recycling per year. Figure 41 shows that a coating can increase
the number of load cycles by a factor 4. (drops of lubricant/produced part);
- Amount of scrap production (number of waste products or kg of
burr/production run or time magnitude);
- Increased productivity (number of produced parts/tool).
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Cross-media effects
An important cross-media effect is that solid low-friction coatings can have poor heat
dissipation with low thermally conductive lubricants, such as polymer-based films.
Therefore, it is important to know the main function of the coating and lubricant for a
given application.
The application of solid low-friction coatings requires additional technologies and
techniques, which represent an additional energy use.
As illustrated in Figure 41 coatings do not prevent the use of lubricants. The lubricant,
in combination with a coating, can further increase the number of cycle times. Doing
so offsets a large number of the benefits related to the elimination of lubricants. The
largest environmental benefits are obtained if no lubricant is used.
Limited literature is available on the toxicological effects of these coatings. As they
have a high resistance, the amount of materials sets free during the use will be low.
Operational data
Because there is no vapour present between lattice plates, MoS2 is effective in high-
vacuum conditions, under which conditions graphite will not work. The particle size
and film thickness are important parameters that should matched with the surface
roughness of the lubricated component. Particle size selection is much important for
rough cut surfaces, such as hobbed open gears, than for highly finished surfaces, such
as those found on bearings. Improperly matched particle sizes may result in excessive
wear by abrasion caused by impurities in the MoS2.
The temperature limitation of MoS2 at 400°C (752°F) is imposed by oxidation. MoS2
oxidizes slowly at atmospheres up to 600°F. In a dry, oxygen-free atmosphere it can
function as a lubricant up to 1300°F. The oxidation products of MoS2 are molybdenum
trioxide (MoO3) and sulphur dioxide. MoS3 is hydroscopic and causes many of the
friction problems in standard atmosphere. MoO3 is a preferred form of the metal used
as an additive for various other metals, which is its primary use.
The issue of where MoS2 should be used, versus graphite or tungsten disulphide, is
generally best addressed by a lubrication engineer. For most commercial applications,
these are relatively simple choices. In aerospace applications where unique
environments and exotic materials are employed, these questions often take
substantial research to provide the best answers (Climax Molybdenum Company,
2015). The low friction coefficients of MoS2 often exceed that of graphite (Machinery
Lubrication, 2015).
Applicability
Almost all metallic products or tools can be coated with a certain type of solid low-
friction coating. The technique is mostly used for turning, moving pieces in tools and
equipment. Applications include piston skirts, bearings, splines, slides, shafts,
plungers, gears, etc.
Due to the existence of different application techniques all product dimensions going
from small up to very large products can be coated (only limited by the specific limits
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of the coating equipment). Since the coating technique is an additional technology,
every company can, at any time, start to incorporate solid lubricant coatings in their
products or processes. Due to the existence of job coating companies, even the
investment of coating technology and knowledge is not necessary. Job coating gives
the opportunity to subcontract the application of the coating with no impact on
existing production within the manufacture site.
Certain production parameters need adaptation to get the highest performance with
the coated products. In fact, a portfolio of different solid low-friction coatings at
different companies depending on the specific application or use exists or it is
compiled by the sector companies in order to have a guidance on which coating
technology is suitable. Nevertheless it can be difficult sometimes to find the right
coating for a certain application. Experts can support companies in the selection of the
most suitable coating solution.
Economics
Solid low-friction coatings can improve process conditions, give and added value to a
product and increase the life time of the products.
It makes the use of lubricated surfaces possible in processes where liquid lubricants
are not possible (food and medical processes (e.g. medication production) or dust
environments), which makes it a cost-effective solution.
Driving force for implementation
The main driving forces for applying solid low-friction coatings are:
- Less downtime for tool replacement;
- Faster throughput time;
- Cost savings on new tools;
- Less scrap production;
- Added value products;
- Coatings readily available and mature deposition techniques with job coating
facilities.
Reference organizations
Oerlikon Balzers: Oerlikon Balzers develops coatings and coating processes, markets
systems and production equipment, contract coating services in a global network are
provided.
http://www.oerlikonbalzerscoating.com/buk/eng/
CSEM: CSEM founded in 1984, is a private applied research and development centre
specializing in micro- and nanotechnology, systems engineering, photovoltaics,
microelectronics, and communications technologies.
http://www.csem.ch
Dow Corning: http://www.dowcorning.com
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Sirris Smart Coating Application Lab: The Smart Coating Application Lab offers support
to technological companies that want to innovate their products with functional
coatings.
http://www.smartcoating.be
Reference literature
Climax Molybdenum Company, 2015, available online at:
http://www.climaxmolybdenum.com/, last accessed on 28th September 2015.
Machinery Lubrication, 2015, Solid Film Lubricants: A Practical Guide, available online
at:
http://www.machinerylubrication.com/Read/861/solid-film-lubricants, last accessed on
28th September 2015.
Miyoshi, 2007. Solid Lubricants and Coatings for Extreme Environments: State-of-the-
Art Survey, NASA, Glenn Research Centre, Cleveland, Ohio.
Oerlikon Balzers, 2010. Coated Components. Greater performance and reliability. 3e
edition, November 2010.
Wu, L., Guo, X., Zhang, J., 2014. Abrasive Resistant Coatings—A Review. Lubricants 2
(2), 66-89.
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2.3.2. Application of wear- and corrosion-resistant coatings of tools and
equipment
Description
In the Fabricated Metal Products sector wear-resistant coatings are applied to increase
the lifetime of products and components. Typical applications for wear-resistant
coatings are punching, forming, machining and moulding in manufacturing of
products. Techniques to apply wear-resistant coatings are mostly PVD (Physical
Vapour Deposition), CVD (Chemical Vapour Deposition), plating, laser cladding,
welding or thermal spraying and all their variations. The coatings applied are mostly
much harder than the underlying bulk material, increasing the wear-resistance.
Coating thickness is in the range of a few µm for PVD up to mm in case of cladding
and welding. Some coating processes, e.g. welding and spraying, are mobile which
means that a (re)application of a wear-resistant coating can be performed on site for
large tools and machine components/equipment.
There exists a large portfolio of different wear-resistant coatings depending on the
specific application or use. However, it can be difficult sometimes to find the right
coating for a certain application37.
Corrosion-resistant coatings, sometimes combined with the functionality of wear-
resistance, protect the underlying material from corrosive elements. Corrosion
processes not only influence the chemical properties of a metal, but also generate
changes in its physical properties and its mechanical behaviour. Corrosion leads to
direct costs for replacing damaged material and components and indirect costs, such
as loss of production, environmental impacts, transportation disruptions, injuries, and
fatalities.
The corrosion-resistant coatings are metallic, organic or inorganic. A wide variety of
corrosion-resistant coatings are available to match the performance requirements of a
specific application, e.g. resin/lubricant blend offering corrosion protection, a
fluoropolymer, ferrous metal coating for anti-galling and minor corrosion resistance,
high gloss topcoat for epoxy and inorganic zinc, abrasion-resistant coating that
protects by binding ceramic particles to a resin system, etc.
The techniques for applying the coatings can be used in the own machinery of the
Fabricated Metal Products companies (Table 27). In case the company
produces/manufactures tools and equipment for other industries, these practices can
be applied as well.
The coating application is an additional process, which any company from the sector
can incorporate at any time at their processes and/or products. Due to the existence
of companies which offer coating services for tools and equipment for companies from
37 TiN, CrN, TiC, CrC, TiAlN, AlTiN are all thin wear-resistant coatings but the
performance of the different coatings depends on the application (temperature, speed,
load, counter material)
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the sector, the investment of coating technology and knowledge might not be
necessary.
Table 27. Application of surface treatment processes (Oerlikon Blazers, 2010)
Protection
against
scuffing
Protection
against
abrasion
Protection
against
corrosion
Application areas
Electroplated hard
chrome
+ ++ + Chemical apparatus,
food industry,
hydraulics
Electroless nickel plating + + +++ Chemical apparatus,
food industry,
hydraulics
Diffusion processes
(nitriding,
nitrocarburisation,
boronising)
+ ++ + Engine components,
tools
Plasma spraying + ++ ++ Turbine vanes
CVD (thermal) ++ ++ + Tools
PVD hard coatings
(TiN, TiCN, TiAN, CrN)
++ ++ + Tools, machinery,
engine components,
motor sport
PVD/PACVD carbon
coatings (WC/C, DLC)
+++ ++ ++ Machinery, engine
components, motor
sport
Achieved environmental benefits
Wear- and corrosion-resistant coatings can lead to a more efficient and a reduction of
resource use, i.e. use of new materials for making new products.
Furthermore, due to the extended lifetime, there will be a reduced manufacturing of
new products to replace the worn products with all environmental issues involved
(carbon emissions, energy consumption, etc.).
PVD and CVD depositions take place in a vacuum chamber making it a very clean,
ecological, healthy process compared to other techniques.
Appropriate environmental indicators
Appropriate environmental indicators are
- Extended lifetime of tools (number of processed parts/tool);
- Decrease in materials for new tools (number of tools /production batch);
- Higher quality production (less non-conformal parts/ production run);
- Less cooling/lubricating fluids (litres/production run).
Cross-media effects
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The aim of wear- and corrosion-resistant coatings is to extend the lifetime of tools and
equipment by using, in many cases, rare materials. Therefore an overall analysis of
the lifetime is needed, to avoid the reverse effect.
The different coating technologies differ largely in energy consumption for applying
the coating, e.g. plating requires less energy than PVD. On the other hand the
emissions related to the processes differ as well, e.g. plating produces significant
waste streams, while PVD has almost no emissions. However, the environmental
impact of applying a coating to reduce wear and corrosion remains limited compared
with the environmental impact of not applying a coating.
Operational data
Sandvik (2008) indicates that the application of a coating has significant beneficial
effects on the overall cost. Figure 42 shows the sources of cost in a typical machined
part. Because machine and labour costs are so high, higher productivity and efficiency
offer the best chance for significant savings. Table 28 shows that increased
productivity by using high quality tools, e.g. treated with wear- or corrosion-resistant
coatings, offers more potential in cost reduction than a 30% discount on the tool cost
itself.
Table 29 gives some examples of wear-resistance coatings on moulds and the longer
lifetimes for those moulds.
Figure 42. Machining cost and impact of a 20% increased cutting speed with high
quality tools (Sandvik, 2008)
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Table 28. Machining cost and impact of a 20% increased cutting speed with high
quality tools (Sandvik, 2008)
In euros Today 30% discount 20% increase
cutting speed
Variable Costs
Cutting tools .30 .21 .45
Workpiece
materials
1.70 1.70 1.70
Fixed Costs
Machinery 2.70 2.70 2.16
Labour 3.10 3.10 2.48
Building & admin. 2.20 2.20 1.76
Cost Per Part € 10.00 € 9.91 € 8.55
Savings 1% 15%
Table 29. Examples of longer mould lifetime by using wear resistance coatings for the
production of synthetic materials (FME CWM, 2005)
synthetic
material
not coated coated
number of
injections
coated material number of
injections
mould
(1.2379)
POM 500,000 PVD TiN > 3,000,000
screw
chrome plated
mould
Phenol 3 months (24h
/ day)
Ion
implantation
4 times longer
up to unlimited
mould in steel glass polyester 31,000 Ion
implantation
684,000
mould in steel phenol 100,000 PVD TiN 1,000,000
The application of coatings will lead to an increased productivity (less downtime) and
decrease in throughput time.
Applicability
Almost all metallic and ceramic products or tools can be coated with a certain type of
wear- or corrosion-resistant product ranging from small products like cutting knifes to
very large heavy duty equipment like moulds, dyes, etc.
Correct selection of the coating type in function of the main requirement or
application, i.e. corrosion and/or wear, is of high importance. Coating can be used for
food and medical approved applications, where the coating requirements are more
stringent. The environmental impact assessments in such cases require a more in
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depth analysis taking the full product life cycle (and risks) into consideration
(Benveniste, 2008).
Certain production parameters need adaptation to get the highest performance with
the coated products, e.g. coated cutting tools might require changed cutting process
parameters. Employees need to be aware that products have a coating. Pre-treatment
of the tool during production might need an adaptation period. In some companies,
moulds are sandblasted prior to production or in-between to clean the surface. When a
coating is applied, such a sandblasting pre-treatment could damage the coating.
Economics
The cost associated with the application of a coating is in most cases low compared to
the great advantages of lifetime extension of tools and equipment. Sandvik (2008)
indicates that the overall benefits of an application with a coating are higher than the
cost savings of buying an uncoated tool (cost of an new uncoated tools is 30% lower
than of a coated tool).
Furthermore, subcontracting the application of the wear- or corrosion-resistant
coatings has advantages that there is no impact on the existing production in the
company and often leads to efficient resource expenditure.
Driving force for implementation
The main driving forces for implementing wear- or corrosion resistant coatings in the
Fabricated Metal Products sector are:
Less downtime for tool replacement;
Faster throughput time;
Cost savings on new tools/equipment;
Less scrap production;
Higher quality products;
Added value products.
Reference organizations
Tata Steel Europe. Tata Steel Europe provides different steel products with wear-
resistant coatings. Examples of their products are: boom arms, powered roof
supports, chassis and base plates, safety-related structures.
http://www.tatasteeleurope.com/en/products-and-services/long/plate/high-
strength/high-strength
Ionbond. Ionbond provides highest performance PVD, CVD and PACVD wear
protection, low friction and decorative coatings as well as coating equipment.
www.ionbond.com
Kanigen Group. Specializing in electroless surface treatment of technical products,
Kanigen Group offers several versions of electroless nickel, using the Kanigen®
process. This process gives the plated parts interesting new mechanical and chemical
properties. http://www.kanigen.eu
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December 2015 193
Oerlikon Balzers. Oerlikon Balzers develops coatings and coating processes, markets
systems and production equipment; contract coating services are available.
http://www.oerlikonbalzerscoating.com/buk/eng/
Plasmajet Advanced Coatings. Plasmajet specialises in wear resistant surface
treatment. For over40 years Plasmajet has been developing technical coatings for all
sorts of applications. http://www.plasmajet.be
Sirris Smart Coating Application Lab. The Smart Coating Application Lab offers support
to technological companies that want to innovate their products with functional
coatings. http://www.smartcoating.be
Reference literature ASM International, 2000, Corrosion: Understanding the Basics.
Benveniste, G., 2008, LCA comparative analysis of different technologies for functional
coating in food applications. I-sup conference 2008.
FME CWM, 2005, Dunne deklagen met name via PVD en CVD voor onder meer
gereedschappen, technical note, available online at:
http://www.induteq.nl/metaal-
werktuigbouw/bestanden/TI.05.23%20Dunne%20deklagen.pdf last accessed on 28th
September 2015.
Oerlikon Balzers, 2010, Coated components, greater performance and reliability,
available online at:
http://www.oerlikon.com/balzers/ last accessed on 28th September 2015.
Sandvik, 2008, The New Rules of Cutting Tools - Rule #4: Focus on the Biggest
Sources of Expense, Modern Machine Shop.
Schmitt G., 2009, Global Needs for Knowledge Dissemination, Research, and
Development in Materials Deterioration and Corrosion Control, white paper, the world
corrosion organization.
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2.3.3. Selection of coolant as environmental and performance criterion
Description
The main aim of coolants or cutting fluids in general is to avoid overheating of
machinery/tools and to lubricate the cutting surface to facilitate cutting and avoid local
welding. In the 1980’s the cost of coolant acquisition, circulation and disposal was
around 3% of the total part cost, while nowadays it reaches up to 16% (Kauppinen,
2002; DGUV, 2010, Error! Reference source not found.). More complex cooling
systems, increased price for purchasing and disposal of coolant and more demanding
machinery tasks are the reasons for the increased cost. The increased cost results in a
moving trend from wet machining to dry machining.
Furthermore bad cooling techniques reduce the lifetime of machinery considerably.
Figure 43. Metal working fluid (MWF) costs in metal machining (DGUV, 2010)
There are two main trends in eco-efficient cooling in machining operations:
- Cryogenic cooling;
- Minimum Quantity Lubrication.
Cryogenic Cooling
Compared to typical coolants (oil or emulsion), cryogenic cooling solutions (with liquid
CO2 and a temperature of approximately -80°C or with N2 and a temperature of
approximately -196°C) offer the most promising results. Due to their strong cooling
capacity, the positive effect on tool wear, part quality and machining speed is big.
Therefore, cryogenic solutions (Error! Reference source not found.) have a high
impact on resource use. Companies that use cryogenic cooling increase their
productivity (Error! Reference source not found.) and reduce the use of energy
and others consumables considerably.
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Figure 44. Cryogenic cooling solution on milling tool (Composite machining, 2014)
Figure 45. Tool lifetime in turning with Liquid Nitrogen Coolant (LIN) compared to Dry
and Regular Cooling (AMT, 2015)
Minimum Quantity Lubrication (MQL)
MQL is a technique with pulsed oil in pressed air using less lubricoolant compared to
wet techniques (Error! Reference source not found.). There are less thermal
shocks and the cooling is very consistent compared to traditional cooling systems. This
results in a longer lifetime of machinery/tools and increased cutting speeds. The
cooling is also more focused on the cutting point and there is no spreading of oil at the
machine. The surface quality is often better and the cooling costs are lower.
MQL is driven by tool and coating design. Development in tool material and coatings
allow machining with less cooling. MQL fits well together with new coatings and this
allows a more environment-friendly process.
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Figure 46. Wet and MQL cooling (Guhring, 2013)
Achieved environmental benefits
The application of cryogenic cooling can, depending on the workpiece material,
significantly decrease throughput rate (due to increased machining efficiency) and
therefore also the energy consumption per produced part. Next to this, the longer tool
life decreases the amount of required tools and avoids excessive waste.
An important advantage of cryogenic cooling is the fact that CO2 and N2 can evaporate
and solve in the air, without any harmful impact on the operator. These benefits are
very important compared to the oils and emulsions which are difficult to recycle, and
which cause harmful emissions.
Appropriate environmental indicators
Appropriate environmental indicators are:
- Emissions of oil emulsions to air and water (l emulsion/machine hour);
- CO2-emissions to air, due to lower energy use (kWh/production batch);
- Longer lifetime of machinery / tools (number of tools per production batch).
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Cross-media effects
The production and storage of liquid CO2 or N2 result in energy use. The CO2 used is a
by-product of the chemical industry (e.g. production of ethylene, Messer, 2015). The
CO2 of the chemical process is liquefied in the chemical plant (instead of discharged to
the air) and sold to the Fabricated Metal Products industry.
Figure 47Error! Reference source not found. gives an idea of the material,
infrastructure and energy flows for both technologies: Conventional cooling and
cryogenic cooling.
Figure 47. Comparison of flows in conventional and cryogenic machining (Pušavec and
Kopač, 2011)
Table 30. Comparison of the LCA of emulsion and cryogenic cooling (Pušavec and
Kopač, 2011)Error! Reference source not found. gives an overview of the LCA of
both machining emulsions and liquid nitrogen as cooling fluid. Conventional emulsions
contain approximately 1.5% mineral oil, 97% water and 1.5% surfactants. Liquid N2
causes less waste at each level, except that it needs cooling water during the “freezing
process”.
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Table 30. Comparison of the LCA of emulsion and cryogenic cooling (Pušavec and
Kopač, 2011)
During a sub-zero cooling of the tool, it is possible that there are side effects in the
product material. The work piece is also “frozen”, and this is not always allowed.
Operational data
It is important that operators use the optimal cutting conditions. The cooling must be
chosen taking into account the material type, the coating and the tools.
Case study – Inconel – (SI)– cryogenic cooling
At the University of Slovenia (Pušavec et al, 2009, 2011), a case-study involved a
comparison between conventional and cryogenic cooling of Inconel. The total sum of
production costs (including machining cost Cm, tool cost Ct, electricity cost Ce, cooling
lubrication fluid cost Cclf and cleaning cost Ccl) was made. Figure 48Error! Reference
source not found. shows the differences between the two.
The case study showed that at a low cutting speed (and productivity), conventional
cooling is cheaper. At high cutting speed (and productivity), cryogenic cooling
becomes more interesting.
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Figure 48. Comparison of cost per part (Pušavec and Kopač, 2011)
This kind of comparisons differs of course from case to case (for each
material/tool/cutting condition-combination).
MQL
Lubricant is supplied by means of a minimum quantity lubrication system (MQL
system). Application of a targeted supply of lubricant directly at the point of use
lubricates the contact surfaces between tool, work piece and chip. The lubricant is
either applied from outside as an aerosol using compressed air or it is “shot” at the
tool in the form of droplets.
Another possibility is internal lubricant feed through the rotating machine tool spindle
and the inner channels of the tool. Figure 49Error! Reference source not found.
shows the basic differences between external and internal feed.
Table 31Error! Reference source not found. gives an overview of the advantages
and disadvantages of both methods.
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Figure 49. External and internal lubrication feed (DGUV, 2010)
Table 31. Advantages and disadvantages of external and internal feed of MQL (DGUV,
2010)
Applicability
Cryogenic cooling can be used for milling of hardened metals (and composite
materials) with ceramic tools and turning.
MQL can be installed for all materials, but sometimes there is a need for a better
cooling capacity. For hard machining MQL is very interesting, but when thermal
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aspects are very crucial other cooling types such as oil/emulsion have better (cooling)
capacities and are sometimes necessary. Table 32Error! Reference source not
found. and Table 33Error! Reference source not found. give an overview of the
different areas where MQL can be used. External feed can be used for retrofit of
conventional machines.
Table 32. Areas of application for minimum quantity lubrication and dry processing
(DGUV, 2010)
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Table 33. Examples of areas of minimum quantity lubrication application with
production processes and motivation (DGUV, 2010)
Economics
The main economic advantage of cryogenic and MQL cooling is a reduction in
machining times, which will on its turn, result in a reduction in lead times (up to
60%). Next to this, the longer lifetime of tools (up to 3 times) and the increased
quality of parts will greatly reduce costs as well (5ME, 2015).
Care should be taken to avoid excessive use of cryogenic coolant due to its large cost
(around 100 euro/tonne for CO2).
For MQL, the initial tooling costs are a little bit higher but the overall process is much
cheaper as shown in Error! Reference source not found.
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Figure 50. Saving potential for MQL (Guhring, 2013)
Cooling consumption can be reduced by a factor 30 for the same productivity and
quality. Costs are halved in comparison to standard (oil/emulsion) cooling. This has a
large impact on the environment (Ward, 2013). The productivity can be increased with
20%.
Driving force for implementation
Import driving forces for implementation are:
Cost saving;
Higher productivity;
Higher quality;
Reducing oil emission;
Human health.
Reference organizations
Ford: MQL uses an extremely small amount of oil versus conventional wet-machining.
For a typical production line of 450,000 vehicles, MQL can save 282,000 gallons of
water per year (Ford, 2013).
5ME (US): provider of cryogenic machining equipment. http://www.okuma.com/5me
Audi (Hungaria Motor Kft.) Audi Hungaria Motor Kft. in Györ is one of the most
important suppliers of engines for Audi and the Volkswagen Group and is EMAS
certified. The use the MQL technology (EU, 2015).
Reference literature
5ME, 2015, Case study: cryogenic machining of modified 4340 steel, available online
at:
http://5me.com/wp-
content/uploads/2014/04/5ME_Cryo_Case_Study_Modified_4340_Steel.pdf
Website visit on 22 June 2015
AMT, 2015, AMT online, available online at:
http://www.amtonline.org/TechnologyandStandards/ResearchDevelopment/
Website visit on 22 June 2015
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December 2015 204
Composite machining, 2014, Sustainable machining with cryogenic cooling, available
online at:
http://compositemachining.org/2014/12/sustainable-machining-with-cryogenic-
cooling/
Website visit on 22 June 2015
DGUV, 2010, Minimum quantity lubrication for machining operations, Nov 2010,
available online at:
http://publikationen.dguv.de/dguv/pdf/10002/i-718e.pdf, last accessed on 28th
September 2015.
EU, 2015, EMAS Case Studies, Audi Hungaria Motor Kft. – Hungary, available online
at:
http://ec.europa.eu/environment/emas/casestudies/audi_en.htm, last accessed on
28th September 2015.
Ford, 2013. Sustainability report 2013/2014. Case Study: Ford Manufacturing Water
Saving Technologies, available online at:
http://corporate.ford.com/microsites/sustainability-report-2013-14/water-saving.html,
last accessed on 28th September 2015.
Guhring, 2013. Technical note: Minimum Quantity Lubrication Basics, available online
at:
http://www.guehring.de/pdf/MMS_Grundlagen_Handbuch_en.pdf, last accessed on
28th September 2015.
Kauppinen, V., 2012, Environmentally reduction of coolants in metal cutting.
“Constantin Brâncusi” University – Engineering Faculty – University’s Day - 8th
INTERNATIONAL CONFERENCE, Târgu Jiu, May 24-26, 2002; available online at:
http://www.utgjiu.ro/conf/8th/S3/01.pdf, last accessed on 28th September 2015.
http://www.academia.edu/5406175/A_review_of_cryogenic_cooling_in_machining_pr
ocesses, last accessed on 28th September 2015.
Messer, 2015, bECO2: CO2 recuperatie eenheid, available online at:
http://www.messer.be/messer_belgie/Milieu/bECO2/index.html, last accessed on 22th
June 2015.
Pušavec F., Kopač J., 2011, Sustainability Assessment: Cryogenic Machining of Inconel
718, Journal of Mechanical Engineering 57(2011)9, 637-647
Pušavec F., Stoi, A., Kopač J, 2009, The role of cryogenics in machining processes,
Tehnički vjesnik 16, (2009), 3 4 -10.
Ward, P., 2013. Minimum Quantity Lubrication Systems (MQL). Plant & maintenance,
2013, July/August, 25 – 27, available online at:
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http://www.maintenanceonline.org/maintenanceonline/content_images/p25,27-
28_ME13.4_Lubrication%20edit.pdf, last accessed on 22th June 2015.
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2.3.4. Incremental Sheet metal Forming (ISF) as alternative for mould
making
Description
In the metal fabrication sector complex shaping of sheet metal, e.g. double curved
surfaces, nowadays is performed by processes like deep drawing, rubber forming,
hydroforming, stretch forming, explosive forming or spinning. All of these forming
techniques require the use of one or several moulds. The production of these moulds
is time and material intensive. Typically a mould is made out of metal (due to its
required wear resistance) and is milled starting from a solid block of metal. This
means that a lot of energy is needed to mill and a lot of material finally ends up as
waste. After milling, the mould has to be polished. These processes are economically
viable for large production series. For low production series (e.g. in deep drawing),
sometimes plastic moulds are used. These plastic moulds wear out faster, but are
cheaper (Proven Concepts BV, 2014). Also for the production of composite parts, often
metal moulds are used.
Since production is more and more focused on smaller series, down to one of a kind
and prototypes, another forming process might offer a solution to some of the
problems linked with the classical processes, i.e. incremental sheet metal forming
(ISF). ISF is an umbrella term for a range of processes in which a sheet is formed
incrementally by a progression of localized deformation. The key advantage of ISF
over the conventional sheet forming processes is that no specialized dies are required;
a wide range of shapes can be achieved by moving a spherical-ended indenter over a
custom-designed numerically controlled tool path. Hence ISF is ideal for small-batch-
size or customized sheet products (Cambridge University, 2009).
SF was initially designed with the aim to reduce necessary equipment and to increase
production flexibility. In the simplest configuration (Single Point Incremental Forming,
SPIF) the process build-up consists of a sheet clamping equipment and a
hemispherical punch that incrementally forms the sheet toward a desired geometry by
a proper trajectory on the sheet itself (Figure 51). Such incremental action allows the
manufacturing of complex products avoiding the use of rigid and dedicated clamping
system. Thereby process costs and times are reduced. These advantages took the
researchers studying ISF to the conclusion that this technology is a suitable alternative
to traditional stamping when small lots of high differentiated products have to be
manufactured (Ingarao et al., 2012).
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Figure 51. Process principle of incremental sheet forming, ISF (ISF-Light, 2012)
ISF can be applied for forming a large variety of geometries and has no need for
expensive tooling. ISF can be used for a wide range of materials, e.g. aluminium,
stainless steel, steel, zinc or magnesium. The deformability depends on the material
characteristics and thickness. Processing of parts is much slower than for the classical
forming processes, but the lead times (time-to-market) can be much shorter and
there is almost no influence when design changes occur. ISF can be used for making
sheet metal moulds for the production of composites, e.g. RTM moulds. Since the only
forming process is a contouring operation, the processing time for making such
moulds is significantly less than milling a block of metal, thus reducing energy
consumption and raw material.
Figure 52. Incremental sheet metal forming installation (INMA, 2014)
Configurable (modular) setups are possible, both in size and tooling (Figure 3).
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Figure 53. Platforms used for ISF, from left to right: CNC milling machine, industrial
robot, dedicated machine (Aminio, 2015)
Achieved environmental benefits
The major environmental benefits are the reduction of raw material and energy use
for the applications for which ISF is the optimal choice. The reduction of energy use is
achieved due to a shorter production time (only contouring operation). No energy is
needed for actuating the tooling and no logistics are required for the waste, as no
waste is produced. Also, due to the nature of this process, noise and vibration levels
are low.
Furthermore, environmental benefits of implementing ISF are related to a reduced
time to market, which has an impact on overall resource use.
Ingarao et al. (2012) indicates that, based on experiments, the implementation of ISF
can lead to a reduction of 10% material use compared to more traditional forming
process, in this case stamping.
Ingarao et al. (2013) also analysed the energy consumption of single point
incremental forming processes. Furthermore they presented a comprehensive
energetic analysis of the single point incremental forming process. All machine tools
architectures commonly used to perform SPIF operations have been taken into
account: energy/power consumption analyses have been conducted for a CNC milling
machine, a six-axes robot as well as the dedicated AMINO machine tool was analysed.
It was observed that as a function of the material strength the power/energy demand
monotonously increases. The so-called material contribution share on the total energy
demand accounts for up to 22% for the material with the highest tensile strength in
the considered material set. As far as the sheet positioning is concerned, a significant
influence has been observed on the robot platform: to form the strongest material
considered in the experimental campaign, a variation of 9% in energy consumption
was observed by a limited position shift. The results lead to the conclusion that a
proper machine tools selection linked to an environmental conscious process
parameters selection could result in large electric energy reductions.
Dittrich et al. (2012) presents an exergy analysis of ISF processes and compares two
ISF variants (single and double sided) to conventional forming and hydro forming
processes. The study indicates that, from environmental perspective, ISF is
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advantageous for prototyping and small production runs up to 300 parts (Kellens,
2013).
Appropriate environmental indicators
Appropriate environmental indicators are:
- Reduction of material use:
Comparison of case studies on material consumption between classical process
on mould manufacturing (milling, eroding, etc.) and ISF (deformation of ‘thin’
sheet) and the required material quality/alloy/properties.
o This comparison can be either a full LCA or a simplified LCA based on
semi-quantitative analysis – Y/N.
o Other indicators are, kg material per mould.
- Reduction of energy use:
Comparison of case studies on energy consumption between classical process
on mould manufacturing and ISF. A possible indicator could be kWh/mould,
kWh/product made in this mould.
Cross-media effects
The implementation of ISF in a company in the sector might be less appropriate in
case of heavy duty, high volume or high pressure applications. For some simple sheet
metal forms that can be manufactured by stamping the energy use of the single point
incremental forming process (SPIF) can be higher than the energy needed for more
traditional stamping. Form complexity and thickness of the metal have a significant
impact on the energy use during production (Ingarao et al., 2012).
Operational data
The size of the manufactured metal depends on the platform and setup size of the
installation and typically ranges from 100 x 100 mm up to 2,000 x2,000mm and even
larger. The following platforms can be used, i.e. milling machine, industrial robot,
dedicated machine (Figure 53). Plate thickness typically varies between 0.5 mm and
2-3 mm.
The manufacturing of parts with ISF requires a case by case approach, considering
material properties, features, existing manufacturing capabilities, batch size, post
processing, etc. Considering the relatively low industrial adoption of this merging
technology Fabricated Metal Products companies often choose to be supported by
competent centres for implementation of this technology.
Applicability
ISF can be used for a wide variety of materials and product geometries. Since, in most
cases, no dedicated expensive tooling is required, start-up time is short and
investment is low for prototypes or for manufacturing single parts, small and medium
batch sizes. Ames (2008) indicates several current and potential fields of application of
ISF, based on the component size and the batch size (Figure 54).
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Figure 54. Current and potential fields of application of incremental sheet forming
(Ames, 2008)
For large products a support tool can be required. The product geometry defines the
need and complexity of the support tool. A simple tool can be used in products where
the walls do not include horizontal surfaces. Then the sheet can be supported on the
highest point of the product and form the walls without any extra support. Examples
of these kinds of products and support tool are shown in Figure 55.
Figure 55. Supporting tool in the background of the mould for a bathtub (Nordic
Industrial Fund, 2003)
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Economics
Possible savings related to the implementation of ISF are related to a lower production
cost compared to a traditional forming process, i.e.:
energy cost;
Material cost;
Time to market;
Tooling.
Obviously the savings depend on the part size and shape. A rather shallow part may
require only 10% of material removal by milling, while a deep part may require up to
90% of material removal by milling. It’s clear that in the second case, the savings on
energy cost, material cost and time are a lot higher than in the first case. ISF is cost
effective for small to medium sized series, as it does not depend on complex and
expensive tooling. ISF is typically considered cost effective for a production volume up
to 300-600 pieces. From that volume investing becomes feasible.
The forming costs are about 5 to 10% of the costs of traditional pressing, but the
production speed is also lower. Despite of the slower speed the method is more
efficient when producing single parts or short series. (Lamminen et al, 2003).
Table 34 makes a cost comparison between deep drawn product versus two ISF
processes.
Figure 56. Dimensions of the piece used in this economical calculation (Lamminen et
al, 2003)
Cost of setting up and NC programming is € 50 in both cases. Cost of deep drawing
dies is estimated at € 12,800.
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Table 34. Comparison of deep drawing and incremental sheet forming parameters and
unit costs (Lamminen et al, 2003)
Deep drawing ISF 1 ISF 2
horizontal forming
speed 15 m/min,
vertical feed 0.2 mm
per step, total
length of forming
path 1,465 m
horizontal forming
speed 30 m/min,
vertical feed 0.5 mm
per step, total
length of forming
path 585 m.
Operating costs
(EUR)
40 40 40
Parts per hour 40
Cycle time (min) 1 1h 37 min 19.5
Part cost (without
material)
1 64.8 13
According to these calculations, incremental forming is considered profitable for
production volumes lower than 1,000 parts. If the production volume is higher, deep
drawing is considered more profitable, at least when using the forming parameters
recommended by Aminio (2015). If the research parameters are used, deep drawing is
considered profitable at a production volume of 200 parts. Figure 57 shows a diagram
of the cost for incremental forming and deep drawing as a function of the production
volumes.
Figure 57. Cost comparison diagram for incremental forming and deep drawing
It should be noted that the cost depends highly on the product geometry and can thus
vary a lot. This cost calculation is merely illustrative and although it can be used as
general reference, it should not be applied for other types of products without further
research.
Driving force for implementation
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The main driving forces for implementing ISF are both environmental (energy and
material use) and economical drivers (time to market, lower production costs).
Reference organizations
Beauvary (DE): Beauvary’s activities focus on small-batch sheet metal manufacturing
for automotive and non-automotive.
http://www.beauvary.com/index.php
Ford uses the ISF for low volume products. (3ders, 2013)
OCAS (BE), OCAS anticipates its’ customers’ needs by developing alloys and coatings,
by producing and testing samples and co-develop steel applications. OCAS is equipped
with state-of-the-art R&D tools and facilities in its laboratories. The research centre
valorises know-how by product and solution development (e.g. ISF).
http://www.ocas.be/.
Reference literature
3ders, 2013, Ford’s new freedom fabrication technology cuts prototype process to 3
days, available online at:
http://www.3ders.org/articles/20130703-ford-new-freeform-fabrication-technology-
cuts-prototype-process-to-3-days.html, last accessed on 14th April 2015.
Amino, 2015, Products, available online at:
http://www.amino.co.jp/en/products/243.html, last accessed on 14th April 2015.
Ames, J., 2008, Systematische Untersuchung des Werkstoffflusses bei der
inkrementellen Blechumformung mit CNC-Werkzeugmaschinen. Rheinisch-
Westfaelische Technische Hochschule Aachen, Dissertation.
Cambridge University, 2009, Incremental Sheet Forming. available online at:
http://www.lcmp.eng.cam.ac.uk/wellformed/incremental-sheet-forming, last accessed
on 14th April 2015.
Dittirch, M.A., Gutowski, T.G., Cao, J., Roth, J.T., Xia, Z.C., Kiridena, V., Ren, F.,
Henning, H., 2012, Exergy analysis of incremental sheet forming. Journal of
Production Engineering, 6, 169-177.
Ingarao, G., Ambrogio, G., Gagliardi, F., Di Lorenzo, R., 2012, A sustainability point of
view on sheet metal forming operations: material wasting and energy consumption in
incremental forming and stamping processes. Journal of Cleaner Production, 29-30,
255-268.
Ingarao, G., Vanhove, H., Kellens, K., Duflou, J.R., 2013, A comprehensive analysis of
electric energy consumption of single point incremental forming processes. Journal of
Cleaner Production, 67, 173-186.
Background document on best environmental management practice in the Fabricated Metal Products sector
December 2015 214
INMA, 2014, Innovative Manufacturing Of Complex Ti Sheet Aeronautical Components.
available online at:
http://www.inmaproject.eu, last accessed on 14th April 2015.
ISF-Light, 2012, Incremental Sheet Metal Forming of Lightweight Materials, Cornet -
European Research Programme, available online at:
http://cornet.efb.de/index.php?menuid=22, last accessed on 14th April 2015.
Jackson, K.P. and Allwood, J.M., 2008, The mechanics of incremental sheet forming,
Journal of Materials Processing Technology, 209(3) 1158-1174.
Kellens, 2013, Energy and resource efficient manufacturing. Ph.D. Dissertation,
Faculty of Engineering Science, K.U.Leuven.
Lamminen L., Wadman B., Küttner R., Svinning T., 2003, ProSheet, Prototyping and
low volume production of sheet metal components. Research report. Nordic Industrial
Fund. 25p, available online at:
http://www.nordicinnovation.org/Global/_Publications/Reports/2004/Prototyping%20a
nd%20low%20volume%20production%20of%20sheet%20metal%20components.pdf,
last accessed on 14th April 2015.
Proven Concepts BV, 2015, Product ontwikkeling, available online at:
http://www.provenconcepts.nl/pages/productengineering.html, last accessed on 14th
September 2015.
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2.3.5. Additive manufacturing of complex equipment - flow optimization for
optimal heat transfer and temperature control
Description
Additive Manufacturing (AM) is a term to describe the technologies for building 3D
objects by adding a material, layer by layer, e.g. metal or plastic. Common to AM
technologies is the use of a computer, 3D modelling software (CAD), machine
equipment and layering material. Once a CAD-sketch is produced, the AM equipment
reads in the data from the CAD-file and lays down or adds successive layers of liquid,
powder, sheet material or other, in a layer-upon-layer fashion to fabricate a 3D object.
The term AM encompasses many technologies, including subsets like 3D Printing,
Rapid Prototyping, Direct Digital Manufacturing, layered manufacturing and additive
fabrication (Figure 58, AMazing, 2015).
AM is already used to make some niche items, such as medical implants, and to
produce plastic prototypes for engineers and designers. But the production of more
complex items, such as heat exchangers or critical metal-alloy parts to be used in jet
engines, remains small scale. Although 3D printing for consumers and small
entrepreneurs has received much publicity, the technology could have the highest
commercial impact in manufacturing processes (MIT Technology Review, 2013).
Figure 58: Schematic view of layer by layer build up in additive manufacturing process
An application in the metal fabrication sector, where AM can lead to significant
benefits, is flow optimization for optimal heat transfer and temperature control. A heat
exchanger is such a typical piece of equipment built for efficient ’heat transfer’ from
one medium to another. The media may be separated by a solid wall to prevent
mixing or they may be in direct contact (Sadik & Hongtan, 2002). Due to restrictions
in classical productions methods, the construction of these devices is often not
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optimal. With the new opportunities that AM offers it is possible to create new
geometries that are impossible to manufacture in one piece with conventional
technologies. Because products are built layer by layer, new shapes can be created.
With these new shapes optimal flow paths for heat exchangers can be created, and
this in a smaller volume while still having a larger surface for heat exchange. Due to
the smaller volume, materials are used in a more efficient way compared to the
classical production method (Figure 59).
Figure 59. Hydrauvision heat exchanger ‘Impossible-crossing’ (Compolight, 2015)
The technology or process engineering department in a company in the Fabricated
Metal Products sector can identify where the critical equipment parts are situated and
can therefore play an important role in the application of this technique.
Manufacturing complex equipment by AM requires a strategic plan to implement this
new way of producing. It also requires a new way of thinking. By radically changing
the design of complex equipment a close collaboration can arise between customer
and supplier. This co-development needs to be supported by a high level of
information exchange, which is important for the success of applying AM.
Achieved environmental benefits
The environmental benefits can be subdivided in primary and secondary effects. The
primary effects cover the increased efficiency of material and energy consumption,
better performing heat exchangers, longer lasting products requiring less material to
provide the same or a better functionality. Weight and volume optimization of the heat
exchangers, which leads to a reduced energy consumption for transportation, can be
considered as secondary effects. Furthermore, the possibility AM offers to produce
locally requires less transportation. The technique also leads to a better control of
extreme (thermal) conditions by the heat exchangers, which reduces the wear of
components. A lower risk of emission of gasses/fluids is also recognized since the
complex products are made out of one piece instead of assembled parts.
A LCA study indicates that AM has a lower environmental impact than conventional
machining (Serres et al., 2011). A reduction of material consumption up to 75% and
CO2 emissions to 40% have been indicated (EADS, 2013). Furthermore, AM for
complex equipment can lead to a life time increase for e.g. parts requiring cooling of 2
to 3 times.
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Appropriate environmental indicators
Two environmental indicators can be identified:
- Raw material use during production (amount of material (kg)/product, AM vs.
traditional manufacturing in %,);
- Energy use across entire value chain (amount of energy (kWh)/ product, AM
vs. traditional manufacturing in %).
Cross-media effects
When implementing AM one should take into account the Total Cost of Ownership
(TCO), since the inherent cost of AM is higher compared to traditional processes. To
make it economically valid, companies should consider the complete value chain of
parts. From raw material, production, post processing, warehousing, transport, waste
management, sales to end of life cost. AM has an impact on each of these steps in the
life cycle of the part. This extended impact makes it complex and hard to make an
accurate prediction of costs and benefits.
Same accounts for LCA comparisons. In today’s literature (2015), many elements of
the value chain are simplified or neglected. But, as mentioned above, a holistic view is
needed to make a study valid. The functional unit is the key element in such studies.
To define this one should regard the complete system that will be redesigned for AM.
Typically, when a part is redesigned for AM, existing features are integrated, new
features are added, assemblies are eliminated, etc. This changes the value of the part
that is created. Besides the value of the part itself, due to the nature of producing with
AM, the value of tied up capital of stock parts, the value of the time to market, the
value of local- and extreme production agility and transport should be calculated as
well. (but are hard to calculate)
As showed in the example of Sylvania (see below, Layerwise, 2015) the part itself will
be more expensive to produce with AM. But, by using AM, an assembly of 20 parts
becomes 1 part what makes the part more durable and more effective. This makes
that the production can run more efficient and has to stop less frequent to change the
burners.
Operational data
Hydrauvision is a specialist company in hydraulics. The heat exchanger design utilizes
complex channels and light weigh structures (“lattices”) for optimal flow and heat
exchange (Figure 60). Some identified benefits of AM are a reduced pressure drop
with a factor 10 lower (without post processing), an improved heat exchanging,
reduced weight from 19 kg to 0.74 kg, reduced volume from 2,900 cm³ to 244 cm³
(Compolight project, 2015).
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Three illustrative cases studies published by LayerWise (2015):
i. ADM realized a weight reduction of 75%. Drastic reduction of flow resistance by
defining channel geometry using freeform surfaces exactly according to CAD design.
The circulation properties improved with 80% (Figure 60).
ii. Form freedom allowing products that cannot be made with conventional technology.
Shape complexity is not charged because cost is dependent on the weight of the part.
By manufacturing a single part (instead of an assembled part made by conventional
technology) the operating, installation and maintenance cost can be reduced because
they need to form a hermetically connected part. Also the leakages due to assembly
and fitting issues are resolved (Figure 61).
iii. Better controlled cooling process delivers higher-quality parts that do not warp and
contain fewer hot spots. The cycle time of moulded plastics was reduced with 15%
(Figure 62).
Figure 60. Component
that connects cooling
circuits
Figure 61. Burner
component from for
Diametal
Figure 62. Injection mould insert with
optimal cooling channels
Case study Havels Sylvania (UK) - gas burner (Laserwise, 2015)
A burner produced with additive manufacturing resulted in:
- 50% less burner material;
- Life time extension (triple) due to lower temperatures of burner material up to
several months non-stop operation;
- Lower metal erosion on 90 degree edges resulted in an increased quality of
produced parts;
- Reduced cost and down time: even with burners being ca. 20% more
expensive, the burners are 60% more affordable;
- 3 times less production stops to replace the burner.
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Figure 63. Left: conventional burner consisting of over 20 parts, right: new AM burner
made by AM out of one single piece
Applicability
AM for flow optimization, heat transfer optimization and temperature control can be
best applied in the sector in case of the following characteristics of the complex
equipment/items: complex geometries, internal channels, lightweight structures, low
volume parts and many connection pieces. Furthermore benefits can be achieved with
AM for critical high temperature and/or high cooling requirements and applications and
in case of use of high grade steel alloys (titanium, inconel, cobalt-chrome, etc.).
Economics
In general AM for flow optimization, for heat transfer optimization and temperature
control leads to a better ratio of cost versus efficiency. The main (economic)
advantages are situated in production cost, production time and product quality
consistency, especially for small series/uncommon geometries. Hydrauvision reports
for example a reduced production cost from € 750 to € 530 for a heat exchanger,
mainly due to the more efficient use of materials and energy during production
(Compolight project: http://compolight.dti.dk/).
The economics of AM evolve. Bigger and faster machines, new materials, integrated
post processing and quality control, all enable AM to be more cost competitive.
Although this evolution is significant, the price level of AM will remain higher than for
traditional methods. AM should be used with care and with knowledge. The full
potential of the technology should be exploited to be economically and ecologically
valuable.
Driving force for implementation
The main driving forces for implementing AM of complex equipment, e.g. flow
optimization for optimal heat transfer and temperature control are:
- Increased efficiency of resource use during production (materials and energy);
- An alternative for casting of complex parts requiring less raw materials;
- Reduced cost for small series;
- Increased efficiency of the equipment, e.g. optimal flow in heat exchanger;
- Low weight and small/custom-made volume solutions.
Reference organizations
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Hittech Group BV. Hittech Group is a Group of centrally controlled independent
companies which operates as a system supplier, extended workplace and partner of
OEM companies. Demo products of heat exchanger: Hittech/Within technologies.
Companies – partners for AM of metal products:
Norsk Titanium (NTi) is a Titanium component producer based in Norway that uses its
novel game changing Direct Metal Deposition (DMD)technology to produce high
quality, complex Titanium components for industrial applications
(http://www.norsktitanium.no/en).
Avio Aero is a GE Aviation business which designs, manufactures and maintains
components and systems for civil and military aviation (http://www.avioaero.com).
LayerWise is the first production centre in Belgium that exclusively focuses on the
Additive Manufacturing (AM) process for metal parts (http://www.layerwise.com).
Companies using ADM parts:
Havells Sylvania (http://www.havells-sylvania.com/): producer of lighting. Havells
Sylvania produces metal pieces in lamps with the use of AM.
Diametal (http://www.diametal.be/) is producer metal parts on CNC milling and
turning machines. They use AM for the production of different pieces with a complex
geometry (Metalise, 2015)
Hydrauvision (http://www.hydrauvision.com/) uses AM for the production of complex
heat exchanger (Dormal, 2013).
Reference literature
AMazing, 2015, Additive manufacturing, Amazing, available online at:
http://additivemanufacturing.com/, last accessed on 14th September 2015.
Compolight, 2015, case stories, available online at:
http://compolight.dti.dk/29519, last accessed on 14th September 2015.
Dormal T., 2013, Design for Additive Manufacturing, AFPR AEFA 2013, available online
at:
https://csissaclay.files.wordpress.com/2013/07/aefa_2013_dormal.pdf, last accessed
on 14th September 2015.
EADS, 2013. 3D printing can cut material consumption by 75%, CO2 emissions by
40%. Retrieved from 3ders.org, available online at:
http://www.3ders.org/articles/20131024-3d-printing-can-cut-material-consumption-
co2-emissions.html, last accessed on 14th September 2015.
Layerwise, 2015, Case studies, available online at:
http://www.layerwise.com/industrial/case-studies/
http://www.layerwise.com/wp-content/uploads/layerwise_havells_sylvania_en.pdf,
last accessed on 14th September 2015.
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December 2015 221
Le Bourhis, F., Kerbrat, O., Dembinski, L., Hascoet, J.-Y., & Mognol, P., 2014,
Predictive model for environmental assessment in additive manufacturing. 21st CIRP
Conference on Life Cycle Engineering. Elsevier B.V.
Masalias, M. D., & Furmanski, P., 2011, Thermodynamic optimization of downhole
coaxial heat exchanger for geothermal applications. Warsaw: Warsaw University of
Technology.
MIT Technology Review, 2013, 10 Breakthrough Technologies 2013, available online
at:
http://www.technologyreview.com/featuredstory/513716/additive-manufacturing/,
last accessed on 14th September 2015.
Norfolk, M., & Johnson, H., 2015, Solid-State Additive Manufacturing for Heat
Exchangers. The Minerals, Metals & Materials Society.
Metalise, 2015, Diametal – mixer, available online at:
http://metalise.eu/en/gallery/diametal-mixer, last accessed on 14th September 2015.
Rua, Y., Muren, R., & Reckinger, S., 2015, Limitations of Additive Manufacturing on
Microfluidic Heat Exchanger Components. ASME Journal of Manufacturing Science and
Engineering.
Sadik, K., & Hongtan, L., 2002, Heat Exchangers: Selection, Rating and Thermal
Design.
Serres, Tidu, Sankare, & Hlawka, 2011, Environmental comparison of MESO-CLAD®
process and conventional machining implementing life cycle assessment. Journal of
Cleaner Production 19 (9-10), pp. 1117-1124.
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2.3.6. Multi-directional forging: a resource efficient metal forming
alternative
Description
By forging complex products with a high
variation in cross-section, a significant
amount of material usually ends up in
burrs. In the standard forging process,
material is formed by the pressure from
above, so that the deformed material can
“escape” to each side to form a large burr.
For complex geometries, more than 40%
of the material can end up in the burrs.
These burrs must be removed by
machining in the finishing steps (Figure
64).
A recently developed “burr free” and
multi-directional forging concept reduces
significantly the formation of burrs by
applying pressure in different directions.
This technique can be applied to all
forgeable metals, including steels and
non-ferrous alloys (aluminium, copper,
magnesium, titanium). The process needs
a rethinking of the complete forging
sequence and makes use of dedicated
forging tools. To compensate for the extra
effort and cost associated with the tools,
multidirectional forging is especially suited
for:
Figure 64. Significantly lower burr
percentage: The multi-directionally
forged crankshaft (right) compared with
a conventionally forged one (IPH-
Hannover, 2014)
- Complexly formed components that have a large potential reduction of the burr
formation;
- Production of larger series (magnitude 1000s).
Some examples include crankshafts, connecting rods, worm wheels, trunnions and
handles.
To implement burr free multi-directional forging, companies can take following steps:
(1) Development and simulation of the process steps
In this phase, the new forging concept, consisting of a sequence of (typically 4)
forging steps, is developed. To do this successfully, a thorough knowledge of the
relevant forging technologies is needed to select the optimal forging concept.
Eventually, external expertise can be brought in. Usually, this step also requires some
experimental tests. Complementary to testing, it is highly advisable to model /
simulate the forging steps as well, using appropriate Finite Element Modelling. This
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gives valuable information about the quality of the (intermediate and final) forgings
and helps to select optimal process parameters without excessive numbers of physical
experiments.
(2) Implementation of the forging sequence and forging tests in industrial
environment
In this step, the practical implementation of the multi-directional forging concept is
worked out. This includes:
- Identification of which machines (e.g. forging presses) will be used;
- Development of the forging tools (based on the findings of the previous step)
including forging tools designs and heating concept.
(3) Validation of the process sequence and the resulting materials and component
properties
In this final step before real industrial production, a test run is performed to validate
the new multi-directional forging concept. Do the forgings have the required
properties? Is the quality consistent and reproducible? Possibly, some minor
modifications or “fine-tuning” are needed in this step.
Figure 65. Examples of components that can benefit from burr free and
multidirectional forging (Hatebur, 2015)
Achieved environmental benefits
Direct effects are the reduced formation of burrs, which leads to a reduction of the
material needed to produce the work piece. The actual material savings will depend on
the specific material and geometry of the work piece. In the case of the two cylinder
crankshaft (elaborated in the REForCH project), burr formation was reduced from 54%
to 7% (which corresponds with a raw materials reduction from 10.8 to 7 kg needed to
make the same component) (Forging magazine, 2014).
It results also in a reduction of (non-hazardous) waste, and the process reduces the
need of finishing machining operations.
The latter leads to a reduction in energy consumption (both related to the machining
itself and the embodied energy in the burrs) and reduces the consumption of cooling
lubrication fluids for the finishing machines.
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In order to compensate the extra heat loss during the multi-directional forging
compared to standard forging, the work piece is extra heated before this step using
for example induction heating. Nevertheless this extra need of energy consumption,
the total energy consumption of the forging process is about 20% lower than for the
conventional forging (REForCH, 2014). This is mainly related to the reduction of the
total weight of the material that must be heated before forging.
Finally, an important environmental benefit is that upstream in the value chain, less
materials must be produced, which leads to a reduction of emissions and resource
use.
Appropriate environmental indicators
Since multi-directional forging leads to savings of material and energy needed to
manufacture a forging, the: following environmental indicators are considered
appropriate:
- Percentage (%) of generated burrs per unit: this indicator describes how
material efficient the process is, and can be calculated as the amount of
starting (or input) material minus the net weight of the finished forging
(expressed in kg). This evidently equals the amount of material that is lost in
the different forging steps;
- Total energy required for the forging process, in terms of energy per piece.
Cross-media effects
Although the forging concept and sequence is changed, there is no need to use
different or more chemicals compared to traditional forging. There are no cross-media
effects due to the use of this technology.
Operational data
The burr free multi-directional forging consists of multiple steps: Figure 66. The multi-
directional forging is typically applied at the end phase of the forging sequence (in the
case of the crankshaft, in step 4 out of 5 forging operations). For the work piece, this
corresponds to intermediate parts as illustrated in Figure 67.
Figure 66. Example of a burr free multi-directional forging sequence of a complex steel
part (e.g. crankshaft) (IPH-Hannover, 2015)
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Figure 67. Workpiece stages during the five forging steps that are needed for the
finished crankshaft. The fourth step takes place with the multidirectional tool (IPH-
Hannover, 2014)
In order to minimize formation of burrs, the complete forging concept including the
forging tools for all the different steps have to be adapted. In the initial forging steps,
traditional forging set-up is replaced by a burr free one as shown in Figure 68.
Figure 68. The adapted forging tools and the associated material flow in the burr free
forging concept (b) leads to significant reduction or elimination of burr formation in
comparison with the traditional set-up (a) (c) (IPH-Hannover, 2015)
Also the multidirectional forging step needs a specially developed forging tool. This has
to support proper mass flow in multiple directions during the forging step, and at the
same time limit the occurrence of burrs. Whereas traditional forging tools only move in
one dimension at a time, multi-directional forming tool allow for simultaneous
movement of forming parts in multiple directions. This is important to guarantee for a
high quality and flawless forging part with the right microstructure and materials
properties.
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Figure 69. CAD model of a multi-directional forging tool for the forging of a crankshaft.
The arrows indicate the multiple directions of moving tool parts (IPH-Hannover, 2015)
The tool design must be tailored to the required material flow. Finite element
simulations allow to predict mass flow during forging based on tool geometry, material
properties and process parameters. They are a performant aid to optimize the tool
geometry. The tool concept must also take into account the pressures and
temperature distribution at all stages of the forging process. Application of well-chosen
tool materials, coatings and/or lubricants can enhance tool durability.
Figure 70. Example of a multi-directional forging tool. It not only presses metal into
the form from above but also at the same time from the sides. (IPH-Hannover, 2014).
This tool can typically be used in normal eccentric presses to produce the parts.
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Applicability
Multidirectional forging can be applied to a wide variety of materials (aluminium,
copper, magnesium, titanium) and product geometries. Because of the need of a
dedicated forging tool, this process is especially suited for the fabrication of larger
series of complexly formed components.
Economics
Material costs usually accounts for 50% of the total production cost of the pieces, and
energy about 5%. The reduction of material (minus 45%) and energy (minus 20%)
consumption consequently leads to a reduction of the production cost of about 25%
per piece. Of course, part of this cost savings are offset by the development,
production and validation of the forging tool, so net savings are very much depending
on the production volume (REForCH, 2014).
Driving force for implementation
Implementation of multi-directional forging leads to a saving of both material and
energy resources. This also leads to cost savings from the moment that the start-up
costs (development, tooling) can be leveraged over enough pieces. Consequently,
both economic and environmental drivers are applicable
Reference organizations
Omtas (based in Turkey) – Producer of engine parts: http://omtas.com/
Omtas was one of the partners in the 7th framework project REForch; they implement
the multidirectional forging.
IPH - Institut für Integrierte Produktion Hannover GmbH (spin-off of the University of
Hannover): http://www.iph-hannover.de/de
The IPH - Institut fuer Integrierte Produktion Hannover GmbH is a company providing
research and development, consulting, and training in production engineering.
Through investigating and improving production, they link the science of production
engineering to the manufacturing industry. They are working with an interdisciplinary
team of mechanical engineers, industrial engineers, business data processing
specialists, technical economists, and technicians.
PCC (UK) – their Wyman-Gordon’s Livingston facility in UK, supplies forged products
globally to the aerospace and energy markets. It has a unique 30,000 ton hydraulic
multi ram closed-die press at the heart of the operation, which is supported by heat
treatment, material handling, etc. The 30,000 ton press is capable of multi-directional
piercing and hot die forging of aerospace, power generation, oil & gas and nuclear
components (asymmetric forgings, discs, seamless extruded pipe, valve bodies and
hollow forged T’s). It is the largest of its type in Europe, forging at temperatures of up
to 1200°C. The 9,000 ton pre-forming press prepares the billet for the closed die
forging process, ensuring a continuous smooth operation. CNC technology ensures
repeatability throughout the entire forging operation.
http://www.pccforgedproducts.com.
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Ellwood crankshaft group (US) – producer of metal parts for marine, locomotive, oil &
gas companies, power generation and mechanical presses has two multi-directional
forging presses operation. http://www.ellwoodcrankshaftgroup.com/Vertical-
Integration/Forging.aspx.
Reference literature Forging Magazine, 2014, New Forging Concept Cuts Burr Percentage, Energy, available
online at:
http://forgingmagazine.com/forming/new-forging-concept-cuts-burr-percentage-
energy, last accessed on 2nd September 2015.
Hatebur, 2015, Products, available online at:
http://www.hatebur.com/hatebur-en/products.php, last accessed on 2nd September
2015.
IPH, 2015, Whitepaper “Material- und Zeitsparnis durch Gratlosschmieden von
langteilen” by IPH, available online at:
http://www.iph-
hannover.de/sites/default/files/whitepaper/Whitepaper_Gratloses_Praezisionsschmied
en_2015.pdf, last accessed on 2nd September 2015.
PCC Forged products, 2015, Wyman-Gordon UK Livingston: overview, available online
at:
http://www.pccforgedproducts.com/brands/wyman_gordon/europe/locations/livingsto
n/overview/, last accessed on 2nd September 2015.
REForCH and IPH-Hannover, 2014, New forging procedure reduces the burr 54 to 7%,
multi-directional forging successfully attempted for the first time in an industrial
environment. Press information, available online at:
http://www.reforch.eu/, last accessed on 2nd September 2015.
http://www.iph-hannover.de/de/node/1441, last accessed on 2nd September 2015.
Wipprecht, S., Baake E., 2015, Entwicklung und Optimierung eines
Erwärmungsverfahrens für das ressourceneffiziente Schmieden, related to the
development of adapted heating, Magazine Electrowarme International, 2015-1, p65-
69, available online at:
https://www.di-
verlag.de/media/content/EWI/ewi_01_2015/Forschung_Aktuell.pdf?xaf26a=0260963c
656de3f5f36d3c00a3d08a7f, last accessed on 2nd September 2015.
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2.3.7. Hybrid machining as a method to reduce energy consumption
Description
Within the sector, designers and engineers usually have multiple choices when it
comes to machining technology. Depending on the part geometry, the material type
and the lot size, a choice is made for different subtractive processes, such as drilling,
milling, turning, grinding, and spark erosion. Besides the apparent speed, quality and
geometric freedom related to each of these processes, their environmental impact is
rarely considered at the design phase. However, the choice for one of these processes
can significantly influence the energy use for the creation of a part (Figure 71).
Figure 71: Electrical Energy Requirement for different processes (Gutowski et al.,
2006)
Each technology has a certain process speed (cm3/s) and specific energy requirement
(J/cm3), which eventually determine the overall energy use. However, functional part
requirements, like surface quality, geometric constraints and material properties often
limit the applicability of high speed low (specific) energy processes such as milling and
turning. Manufacturing engineers responsible for overlooking the processes often
choose one particular manufacturing technology based upon these functional
requirements for the final product. However, applying hybrid technologies can
significantly enhance the total energy requirement for the machining of a part. A
hybrid machining process is defined as a manufacturing process which combines two
or more established manufacturing processes into a new combined setup whereby the
advantages of each discrete process can be exploited synergistically (Zhu et al. 2013).
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Figure 72: Hybrid process classification (Zhu et Al. 2013)
As can be seen in Figure 72 hybrid processes can be classified into several major
categories, based upon the combination of machining technologies. Subtractive
processes are e.g. milling, turning and drilling, while additive processes can be
Selective Laser Sintering (SLS), Selective Laser Melting (SLM) and Laser Cladding.
Transformation processes are e.g. laser softening, electrical discharge machining
(EDM) and electrochemical dissolution (ECD). In practice this means for example that
a mechanical conventional single cutting or media assisted (MA) action process can be
combined with the respective machining phases of electro discharge (ED) in electro
discharge machining (EDM) or ECD (Electro Chemical Dissolution) in ECM. The reason
for such a combination and the development of a hybrid machining process is mainly
to make use of the combined advantages and to avoid or reduce some adverse effects
the constituent processes produce when they are individually applied. The
performance characteristics of a hybrid process are considerably different from those
of the single-phase processes in terms of productivity, accuracy, and surface quality.
Furthermore, Zhu et al. (2013) states that hybrid processes open up new
opportunities and applications for manufacturing various components which cannot be
produced economically by processes on their own. Another approach on how to
classify hybrid machining has been proposed by El-Hofi (2005). Depending on the
major machining phase involved in the material removal, hybrid machining can be
classified into hybrid chemical and electrochemical processes and hybrid thermal
machining.
Using hybrid processes, existing technological process limits can be extended by
combining additional sources of energy and conventional existing machining processes
(Table 35).
Table 35. Examples of hybrid machining processes (Fraunhofer, 2014)
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Principle Process variants Motivation for application
Vibration-superimposed
machining
Drilling
Turning
Grinding
Improvement of chip
breaking
Electrodischarge Machining
Electrochemical Machining
Improvement of quality,
productivity
Media-superimposed
machining
High pressure cooling Improvement of chip
breaking
Cryogenic cooling Increase in material
removal rate
Machining with
superimposed
movement of the axis
Scissors kinematics Increase in dynamics in die
and mould making
Out-of-round machining by
Adaptronic form honing and
boring
Improvement of the
operating properties of
engines
To achieve this, the machining process has to be broken down in different steps and
the functional requirements for each step have to be listed. Based upon this, the most
suitable technology for each step can be chosen taking energy consumption into
consideration. In general, this will result in one or more roughing operations with one
fast and energy efficient technology. While the finishing operation will be slower and
more energy consuming, resulting in an overall lower energy consumption compared
to the situation in which only the finishing technology is used based upon the
functional requirements of the part.
Achieved environmental benefits
When combining energy efficient technologies (conventional processes as shown in
Figure 71) with advanced processes compared to using solely the advanced processes
there are several significant advantages:
- Lower lead times due to faster machining processes;
- Lower energy use and CO2 emissions;
- More efficient use of consumables leading to less hazardous waste and
emissions;
- Overall lower operating expenditure (OPEX).
Appropriate environmental indicators
An appropriate environmental indicator is the energy consumption (kWh machine
consumption per batch).
Due to the synergies between the two interacting processes in hybrid machining, the
overall machining process is more efficient than the sum of its parts. This efficiency is
in general expressed in machining time, tool wear, spindle power, electrode
consumption, cooling water consumption or compressed air consumption. These
combined lead to less energy use during the hybrid machining process and less raw
material use (resulting in an overall reduction of CO2 emissions).
Cross media effects
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Hybrid machining requires initially more investments in hardware and has therefore
also an influence on the environmental impact due to the production of these
machines. In addition, extra cooling water or compressed air circuits can be required
for hybrid machining processes, offsetting the energy gains made by them. Care
should be taken that these factors are taken into account when considering hybrid
manufacturing.
The highest benefit is achieved if the different operations/processes can be installed
on the same machining platform. When two separate platforms need to be used, the
investment cost might offset the benefits.
Operational data
A good example is the use of a hybrid micro-milling/micro-edm system, as can be
seen in Figure 3. The roughing operation is performed by micro-milling, which has a
lower specific energy consumption compared to micro-EDM (electro discharge
machining). The finishing operation, which is slower and more energetic, is performed
by means of micro-EDM milling, since the accuracy and surface quality achieved with
this technology is significantly better than with micro-milling. However, combining
these two technologies leads to overall improved energy efficiency if only micro-EDM
is used based solely upon the part requirements. In this case the Sarix SX200
platform is used to install sequentially the milling and EDM features.
Figure 73: Hybrid micro Milling/EDM machine (WZL, RWTH Aachen)
Applicability
Different subtractive and additive machining technologies can be used to machine or
form a product. For example, hybrid lathes, which combine laser softening with
turning, allow faster and more energy efficient material removal compared to either
conventional turning or laser ablation. In general, this method can be applied to nearly
all processes as long as the combination of technologies offers a substantial increase
in performance and/or capabilities.
Economics
A substantial reduction in operating costs is expected due to lower lead times, less
consumables, more efficient use of coolant/dielectric and lower energy use. However,
additional investments are expected for the machine itself and/or additional
infrastructure. An example for laser assisted machining (LAM) is shown in Figure 4.
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Conventional turning with Carbide inserts is compared to conventional turning with
ceramic inserts, both with and without the assistance of a laser which softens the
material before chip formation. The result is a drastic reduction of 50 % for the
machining of 1m of Inconel 718 using ceramic inserts compared to classical machining
without laser assistance (Anderson et Al. 2006)
Figure 74: Conventional Machining vs Laser Assisted Machining (LAM) (Anderson et Al.
2006)
Driving force for implementation
Lower lead times combined with lower energy consumption are the main drivers for
implementing hybrid machining in company in the metal fabrication sector.
Reference organisations
DMG Mori. DMG MORI integrates for the first time the additive manufacturing into a
high-tech 5-axis milling machine. This hybrid-solution combines the flexibility of the
laser metal deposition process with the precision of the cutting process and therewith
allows additive manufacturing in milling quality. http://en.dmgmori.com
HAMUEL Maschinenbau GmbH & Co. www.hamuel.de
Yamazaki Mazak manufactures not only advanced machine tools such as multi-tasking
centres, CNC turning centres, machining centres and laser processing machines but
also automation to support global manufacturing by providing exceptional productivity
and versatility (http://www.mazak.eu).
The Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen
University stands for successful and forward-thinking research and innovation in the
area of production engineering. http://www.wzl.rwth-aachen.de.
Reference literature Anderson M., Patwa,R. , Shin Y.C., 2006, Laser-assisted machining of Inconel 718 with
an economic analysis, International Journal of Machine Tools and Manufacture, 46
(2006), 1879-1891.
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Duflou, J., Sutherland, J., Dornfeld, D., Herrmann, C., Jeswiet, J., Kara, S., Hauschild,
M., Kellens, K., 2012, Towards energy and resource efficient manufacturing: a
processes and systems approach, CIRP Annals – Manufacturing Technology, 61, 587-
609.
Kellens, K., Dewulf, W., Lauwers, B., Kruth, J.P., Duflou, J.R., 2013, Environmental
impact reduction in discrete manufacturing: Examples for non-conventional processes,
Procedia CIRP, 6, 27-34.
Gutowski, T., Dahmus, J., Thiriez, A., 2006, Electrical Energy Requirements for
manufacturing processes, Proceedings of the 13th Cirp conference on life cycle
engineering, Leuven, p 623.
Fraunhofer, 2014, Hybrid machining processes in cutting technology. Fraunhofer
Institute for machine Tools and Forming Technology IWU, Chemnitz, Germany.
El-Hofy, H., 2005, Advanced Machining processes. Non-traditional and Hybrid
Machining Processes. McGraw-Hill, DOI: 10.1036/0071466940.
Zhu, Z., Dhokia, V.G., Nassehi, A., Newman, S.T., 2013, A Review of Hybrid
Manufacturing Processes – state of the art and future perspectives. International
Journal of Computer Integrated Manufacturing, 26 (7). pp. 596-615.
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2.3.8. Machining of near-net-shape feedstock
Description
Integrated machining centres and milling machines start in general from generic
feedstock shapes such as metal blocks and rods. However, by using these generic
feedstocks a lot of unwanted material has to be removed and is lost as burrs. A
possible solution for this is to start from near net shapes (Figure 75). Near net shapes
are defined as products which initial production is very close to the final geometry,
limiting the amount of unwanted finishing operations. Well known neat net production
technologies are gel casting, injection moulding (ceramic, metal and plastic), casting,
cold forming, spray forming, Selective Laser Sintering (SLS), Direct Metal Laser
Sintering (DMLS). For example, injection moulding starts from powders (ceramics,
metals) and results in a near net shape in which very often the only finishing is the
removal of burrs, runners and/or machining within final tolerances. Up to 66% of the
total production cost is hidden in this finishing operation, meaning that limiting them
can be of great advantage for a company. In particular for expensive materials, such
as titanium near net shapes are particularly interesting.
Figure 75: Near net shape machining (Whitesell group, 2015)
The feedstock material used depends on the type of near net shape process and the
material. In the metallurgical processes, with exception of casting, a powder in which
metal powders are mixed with polymer additives is formed, to a green compact and
then sintered to achieve a solid near net shape (Figure 76). These products are Metal
Injected Moulded (MIM). The powder composition, the size and the process conditions
play an important role in the final product quality. They also influence the required
finishing operations. Controlling shrinkage is for example vital to insure a minimum of
stock remains for the finishing process.
Depending on the application and the material, a near net shape technology can be an
option. Larger metallic parts are usually formed by means of casting, while mass
produced smaller components are MIM’ed. In general, it is expected that by using a
powder metallurgical process, the energy requirement to create the part material will
be much lower, since this takes place far below the melting temperature of the metal
and is based upon atomic diffusion and energy minimization (sintering). The majority
of the near net technologies in metals are based upon this principle.
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Figure 76: Flowchart of MIM (Afraz, 2012)
The use of near net shapes therefore does not only require knowledge regarding the
suitability of a certain near net shape technique for milling or turning, but also a
logistical approach. Designers and production engineers therefore should work closely
together.
As the amount of burrs is reduced, the amount of non-hazardous waste is reduced.
Traditionally this waste will be recycled to the ferrous or non-ferrous metals industry.
Achieved environmental benefits
The use of near net shapes greatly reduces the amount of lost material during
conventional machining. In addition, due to the much lower machining time, the
consumption of electrical power, coolant and compressed air and tool wear are
significantly reduced. This is however offset by the additional energy and consumable
use for creating the neat net shape.
The material and consumable savings result in a significantly lower amount of CO2
emissions, lower amount of waste materials such as slags, refractories, electrodes,
gases, etc. (Whitesell group, 2015; Plymouth, 2015).
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Appropriate environmental indicators
The Percentage (%) of metals which end up in the burrs during the production of a
metal piece is the appropriate environmental indicator.
Energy use and CO2-emissions compared to machining conventional feedstocks due to
less overall material removal can be measured by a LCA study.
Cross media effects
There are no negative effects on other environmental compartments due to the use of
this technology.
Operational data
Suitable near net shaping technologies should be listed for each machining
technology, together with material mass/cost, production cost. Ideally, a cost/kg for
the finished product with near net shape should be determined and compared to the
cost/kg when starting from a generic feedstock material.
The use of near net shapes greatly reduces the amount of lost material during
conventional machining, which can mount up to 60-70 % of total mass in some cases
(Whitesell group, 2015; Figure 77, Salvendy, G. 2001).
Figure 77: Cold forming as a near net shape technology to allow less material waste,
lower cost and lower lead times (Whitesell group, 2015)
Applicability
Forged, cold formed parts, SLS and SLM sintered parts, injection moulded parts can be
used as feedstock material for lathe’s, milling machining, EDM and ECM to lower the
overall environmental and economic cost.
The environmental and economic benefits depend greatly on the cost of creating a
near net shape instead of starting from generic feedstocks and/or the cost for any
additional logistical support such as robots to insert and clamp the part in the
machine.
Economics
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Lower machining times (up to 70 % reduction) combined with 60-70 % reduction in
material use lead to significantly lower total costs compared to generic feedstock
processes. This is offset by the cost for the creating the near net shape.
Driving force for implementation
Driving forces for implementation are:
Cost reduction;
Lead times reduction;
Material availability.
Reference organisations
ASCO (Zaventem) is supplier and manufacture of high lift structures, complex
mechanical assemblies and major functional components. ASCO uses titanium forge
pieces instead of solid titanium blocks to lower machining time, tool wear, material
waste and thus overall cost.
PMF industries (US) uses Near Net shape to produce different metal pieces for the
food, pulp and paper industries, for medicals and other industries.
http://www.pmfind.com/
Reference literature Afraz S.A., 2012, Mechanical, Microstructural and Corrosion performance for MIM
materials based on coarse (-45µm) powders of ferritic stainless steel, thesis, available
online at:
https://www.diva-portal.org/smash/get/diva2:645080/FULLTEXT01.pdf, last accessed
on 8th October 2015.
ASCO, 2015, available online at:
http://www.asco.be, last accessed on 4th June 2015.
Plymouth, 2015, Near Net Aerospace Extrusions, advantages, available online at:
http://www.plymouth.com/products/plymouth-engineered-shapes/near-net-
aerospace-extrusions/, last accessed on 4th June 2015.
Salvendy, G. 2001. Handbook of industrial engineering: technology and operations
management, edited by Gavriel Salvendy – 3rd ed. 2753 p. (Near net shape 563 to
588).
Whitesell group, 2015, available online at:
http://www.whitesellgroup.com/product-coldformlarge.html, last accessed on 4th June
2015.
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2.3.9. Reduce the energy for paint booth HVAC with predictive control
Description
In the BEMP 2.2.6 (Efficient ventilation), different steps for optimizing ventilation are
described. One of the practices described is ventilation according to needs, by means
of a central steering unit, which links data on machines with the ventilation valves
(feedback control). The present BEMP focusses on the paint booth in the finishing step
of Fabricated Metal Products companies, and will lead to a further reduction of the
environmental impact of the heating, ventilation and air conditioning (HVAC).
HVAC for paint booths requires the highest energy consumption in painting facilities.
To evaporate the solvent (oil or water) in the paint, dry air is needed. Depending on
the temperature of the air, there is a limit to how much water vapour it can absorb.
The speed at which the paint dries, depends on the difference between this limit and
the amount of water vapour already in the air. This means that, even when the
temperature or humidity changes, if this “difference” can be kept constant, it is
possible to achieve a constant paint drying speed, and therefore a constant paint
drying time.
Using forward controls on top of feedback controls to manage the optimal working
conditions depending on the incoming air conditions (temperature and humidity), the
energy needs can be reduced.
HVAC systems that automatically determine an optimal control point in accordance to
the outdoor temperature and select the best energy-saving operation mode are
already available. They are often called window control systems (Taikisha-group,
2015).
Figure 78. Control window versus control point (Taikisha-group, 2015)
Conventional water-based painting systems use air conditioning to maintain ideal
conditions by keeping both the temperature and humidity at a fixed level. However,
this consumes a considerable amount of energy, especially in summer and winter, to
heat and cool the air inside and maintain humidity at the prescribed level. But the
evaporation rate could also be controlled by adjusting the humidity level depending on
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the ambient temperature in the paint booth. This means that it is no longer necessary
to maintain a fixed temperature in the booth (Figure 79).
Based on this data, a system continuously controls the maximum water vapour
absorption volume by monitoring the external air conditions and makes the smallest
necessary adjustments to temperature and humidity inside the paint booth. The
system significantly reduces energy consumption (Automotive manufacturing
solutions, 2015).
Figure 79. Situation before: situation of the paint booth with feedback control,
Situation after: situation of the paint booth with forward and feedback control (Toyota
motor manufacturing, 2015 –Personal communication at the Agoria event on
automotive)
Achieved environmental benefits
By using this technology, less energy is needed for conditioning (heating and cooling)
of air for the paint booth. This will lead to a reduction in CO2 emissions and other
emissions due to heating and cooling. In the Toyota case as shown in Figure 79this
has led to a CO2 emission reduction of 62% over 2 years.
Case Study: Honda Marysville, (VS, Ohio) (Kisiel, 2008)
Honda has developed a new air-conditioning control system that has cut energy
consumption by 25% in the paint booths at the assembly plant here. Besides the
reduction in energy consumption, Honda has realized a 24% CO2 emission reduction
from the natural-gas consumption in the paint shop.
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Case study - Saab Automobile’s factory in Trollhättan, Sweden (Rohdin et al, 2012).
In the Saab factory, a variable air volume (VAV) system was installed in the paint box.
The total electric power use after the changes is 30.2%.
When this technology is combined with a change of paint type (water based instead of
oil based) the technology could lead to a reduction in VOC emissions.
Due to a better control of the dry process, the total throughput of the paint booth
could be achieved. Therefore this may lead to shorter curing cycles and eventually to
an overall reduction of the energy use per produced unit.
Appropriate environmental indicators
Appropriate environmental indicators are:
- Energy use for the paint booth in function of the size of the painted units and
the booth, kWh/product painted, kWh/operating time of paint boot or, kWh/per
m³ air);
- Additionally the reduction in energy consumption can be translated into CO2
emission reduction (which depends on the energy type used).
Cross-media effects
There are no cross-media effects due to the use of this technology.
Operational data
Mazda has developed a system that continuously monitors the maximum water vapour
absorption volume to make the smallest necessary adjustments to temperature and
humidity inside the paint booth. This has resulted in a 15% CO2 emission reduction.
Usually the process involves raising the temperature to 80°C until the paint is
sufficiently dry. However, before the clear coat can be applied, the temperature must
be reduced back down to 40°C. This can now be prevented. The technology means the
water can be efficiently removed with the lowest possible electricity consumption
(Automotive manufacturing solutions, 2015).
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Figure 80. Reduction of CO2 and VOC by the use of water based paint and forward
control of the HVAC of the paint booth, comparing to conventional oil based paint and
conventional drying technology (Automotive manufacturing solutions, 2015)
A comparable technology was installed at the Toyota plant in the UK. This has resulted
in a CO2 emission reductions of 65% (Toyota motor manufacturing, 2015 – Personal
communication at the Agoria event on automotive; Honeywell, 2009).
Applicability
This HVAC system is more complex than the conventional ones due to the following
elements:
- Qualified employees with profound knowledge;
- Maintenance and continuous follow up (sensor performance, etc.) to maintain
the effectiveness of the installation;
- Strong and reliable data capturing (sensors, measuring, etc.) and automation.
The technology requires profound knowledge of paint drying process and paint quality
control.
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The technology is implemented in large paint booths using water based paints, but is
probably not applicable for small size paint booths (no information on this available).
The investment and research costs are high, therefore, this technology is easier to be
implemented from companies with multiple paint booths (on one or more locations)
where the gathered knowledge can be valorised.
This is the reason why this technology is applied in automotive companies and no
published case are found (yet, reference year 2015) in other Fabricated Metal Products
companies.
Economics
At Toyota Motor Manufacturing(UK) the energy use in the paint booths was reduced by
25%. This equates to a saving of 4% of the site’s total energy consumption. Toyota
Motor UK expects to achieve a full return on its investment in less than two years.
(Honeywell, 2009)
Driving force for implementation
Main driving forces for implementation are:
- Cost reduction;
- Reduction of emissions and energy use;
- Better control on the quality of the painted pieces.
Reference organizations
Toyota Motor Manufacturing (UK) Ltd, Toyota implemented the technology in the UK
plant.
http://www.toyotauk.com/
Mazda Motor Corporation implemented the system for vehicle body painting at its
Ujina Plant No.1, in Japan.
http://www.mazda.com/
Reference literature Automotive manufacturing solutions, 2015, A green and better paint finish at Mazda,
available online at:
http://www.automotivemanufacturingsolutions.com/process-materials/a-green-and-
better-paint-finish-at-mazda, last accessed on 12th May 2015.
Honeywell, 2009, Honeywell and Toyota Motor Europe Partner to Increase the Energy
Efficiency of European Paint Operations, available online at:
https://www.honeywellprocess.com/en-US/news-and-
events/Pages/PR_10282009_Honeywell-and-Toyota-Motor-Europe-Partner-to-
Increase-the-Energy-Efficiency-of-European-Paint-Operations.aspx, last accessed on
12th May 2015.
Kisiel R., 2008, Weather forecasting cuts Honda's energy use in paint shop,
Automotive News, available online at:
http://www.autonews.com/article/20080811/OEM01/308119935/weather-forecasting-
cuts-hondas-energy-use-in-paint-shop, last accessed on 12th May 2015.
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Rohdin P., Johansson M., Löfberg J., Ottosson M., 2012, Energy efficient process
ventilation in paint shops in the car industry, Ventilation 2012 – template Page 1 / 6,
available online at:
http://www.diva-portal.org/smash/get/diva2:565542/FULLTEXT01.pdf, last accessed
on 12th May 2015.
Taikisha Ltd (UK), 2015, Paint Booth, available online at:
http://www.taikisha-group.com/service/paint_booth.html, last accessed on 12th May
2015.
Sadeghipour E., Westervelt E.R., Bhattacharya S., 2008, Painting Green: Design and
Analysis of an Environmentally and Energetically Conscious Paint Booth HVAC Control
System, American Control Conference Westin Seattle Hotel, Seattle, Washington, USA
June 11-13, 2008, available online at:
http://www.nt.ntnu.no/users/skoge/prost/proceedings/acc08/data/papers/0956.pdf,
last accessed on 12th May 2015.
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2.3.10. Selection and optimization of thermal processes for curing wet-
chemical coatings on metal products
Description
Surface treatment with functional coatings is performed in the Fabricated Metal
Products sector to upgrade a (metallic) surface and provide it with an additional
functionality. The additional functionality can be e.g. scratch resistance, abrasion
resistance, easiness to clean, anti-microbial, soft-touch, etc. The use of a coating is
always an extra step in the manufacturing process. It requires additional effort to
apply, but also to cure the coating. This extra step requires an additional energy input.
Therefore, carefully selecting and optimizing the proper curing process for a given
product can lead to significant energy reduction. Curing of coatings can be done in
various ways depending on the chemical composition of the coating: The industrial
most significant techniques are:
1) Room temperature curing;
2) High temperature curing;
3) Infrared curing (IR curing);
4) UV and UV-led curing.
1) Room temperature curing
Curing at room temperature is the easiest way for curing a coating, but the
formulation has to be made accordingly. Conventional decorative paints cure at room
temperature for example. They are not used for large series in an industrial process
because of the time needed to cure the coating, in case of unique pieces or small
series, room temperature curing is used in the sector.
2) High temperature curing (hot air/convection)
Conventional curing with hot air requires a lot of energy for heating up the air around
the coated surface. Curing with hot air is the least favourable way of curing (in terms
of energy use). But it is easy to apply and all kinds of difficult geometries can be
covered with this curing technique.
Typical curing temperatures can range from 60 up to 200°C depending on the coating
formulation. High solids coatings only need al short flash-off and curing while
formulation with high solvent content need longer curing.
Where time is not a critical parameter, thermal cure coatings can cure on a lower
temperature during a longer time, while the same coatings can be forced cured at
higher temperatures needing less time to fully cure. The first way of approach
obviously requires less energy which makes this the most sustainable option.
3) Infrared curing (CCI Thermal, 2015)
Heating with infrared energy heats up the object by irradiation, and thus the coating is
cured from the inside out, whereas curing with hot air cures the coating for the
outside inwards. For thick coatings this can lead to cracking because a hard thin film is
formed at the surface while the rest of the coating is not yet cured. Remaining
solvents in the coating need to escape and have to find a way through the formed
hard shell leading to cracks.
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The radiant energy of infrared heat is ideally suited to the process of finishing because
the infrared radiation heats from the inside out, ensuring that water or solvents are
forced to the surface and evaporated so they cannot cause blemishes and blistering.
The infrared heating process is the purest and most direct application of heat. Since
infrared energy heats only what needs to be heated - the product and the coating -
less energy and time are required. Infrared curing avoids circulating dust particles that
can ruin the product's finish - unlike conventional convection methods that are
unreliable to control finishing results. Infrared curing, as occurs in an industrial oven
application, applies radiative energy to the receiver, or part, by direct transmission
from the emitter. Some of the energy emitted will be reflected off of the part surface,
some is absorbed into the coating and some is transmitted into the substrate. Infrared
emitters provide a fast cure for coatings but they are sensitive to differences in the
part structure.
IR radiation is a line-of-sight technology, meaning that it only delivers heat to the
surface of an object that is in a direct line of sight from an IR source. When using
complex geometries, with parts that cannot be irradiated with IR, a combination of IR
curing and conventional thermal curing is an ideal solution. Those hybrid systems try
to combine best of both worlds, e.g. hot air infrared drying system (HID). This HID
system leads to an effective heat management and has several benefits (IST, 2015):
- With the HID system it is possible to achieve production speeds, which are
twice as fast as with conventional warm air dryers;
- A combination of high power IR lamps and a high volume of hot air result in an
extremely effective drying system;
- Effective heat management guarantees the optimum temperature on the
substrate for accelerated drying;
- The finely tuned air slit nozzles and exhaust unit ensure effective removal of
the moisture from the substrate.
4) UV and UV-led curing
Curing with hot air and IR can take a while (negative aspect), while curing with UV
hardens the coating in merely seconds. Curing with conventional UV (gas discharge)
also demands high energy input, while curing with UV-led demands much lower
energy input. But there are currently only a handful of coating formulation which can
be cured with UV-led (Koleske, 2002). The UV-curing technology enables ultra-rapid
curing at room temperature, saving considerable time and energy. The coating
formulation has to be formulated accordingly in order to apply UV curing. Curing with
UV needs the presence of photo-initiators in the coating. The coating curing forms a
systems that might require significant process changes and investments. UV-led
curing however is not yet completely integrated because the conventional curing with
UV discharge lamps are more efficient. Also the photo-initiations needed for UV-led
curing still have to be optimized further to ensure complete curing/polymerization of
the coating. UV led compare to convention UV curing has some advantages as shown
in Figure 81.
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Figure 81. Differences between a conventional UV lamp and a UV led for curing (UV
process, 2015)
Achieved environmental benefits
Conventional curing with oven (hot air) is least environmental favourable since
warming up air requires a significant amount of energy. It is clear that the good
selection and optimization of a curing technology for a given product/process will lead
to significant energy reductions.
Figure 82. Ecological fingerprint of six refinish primers (Wall et al., 2004)
Appropriate environmental indicators
Appropriate environmental indicators are:
- Energy use for curing ( kwh/m² coating cured);
- VOC emissions: in case of UV and UV-led curing is introduced, VOC elimination
can be achieved. Solid content determines the amount of VOC emitted. Typical
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hot air cured coatings have a solid content of 30-60%, while UV cured coatings
have a solid content of ~90-99%.
Cross-media effects
Coatings that have to be cured with hot air or IR are mostly low solid content
coatings, which are water based or solvent based coatings. Solvent based coatings
have high VOC content (volatile organic carbons) during curing, leading to a higher
environmental impact. Increased awareness of environmental impact and VOC and
more regulatory requirements in most European countries have led to an increased
demand for more sustainable organic coatings, including for applications on metallic
substrates. Therefore, the market share of solvent based coatings is decreasing in
favour of more sustainable alternatives. Water based coatings and UV-hardening
coatings are possible alternatives.
Curing with UV requires the presence of photo-initiators in the coating which trigger
the polymerisation process in the coating. When this polymerisation is not fully
controlled, e.g. due to over-concentration of photo-initiators or inadequate UV
exposure, they can leach out the ‘cured’ coating. The concentrations of those leached
out photo-initiators are extremely low. However, special attention is required,
especially since they can be toxic. This is the reason why for food and medical
application UV-curing coatings are not yet approved. Many photo-initiators or
monomers are not, or only partially, trapped in the cured ink film and still remain
capable of migration to foods, depending on their molecular weights. Likewise,
decomposition products that are formed during the curing reaction and that are not
trapped in the ink film may be a source of migrating chemicals. The majority of photo-
initiators have not been toxicologically evaluated for food contact application (Sutter
et al., 2011).
Selection of the UV-curable ink components and ink solvents has a significant impact
on hazardous waste, skin irritation, toxicity etc. (Table 36).
Table 36. A comparison of the toxicity & other properties of UV-curable ink
components and some commonly used ink solvents (PNEAC)
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Operational data
Golden (2005) reviewed some case studies related to the application of technologies
for curing coatings. In an organization where surface treatment is applied to
aluminium cans, the original technology (thermal curing of water-borne coatings) was
replaced by an UV-curing process. Even the water-borne coatings contained
substantial quantities of VOC that had to be incinerated. Table 37 shows that although
incineration controls with water-borne inks and coatings can achieve the same level of
VOC and HAP emissions as UV curing, this is at the expense of increased emissions of
hydrocarbons (HC) and carbon, nitrogen and sulphur oxides.
Table 37. Total industrial installation and utility source emissions (metric tons/billion
cans) (Golden, 2005)
Process
Emissions Water-borne
Thermal,
uncontrolled
Water-borne
Thermal +
incineration
UV curing
Nitrogen oxides 8.1 11.6 6.5
Sulphur oxides 18 23 18
Particulates 25 29 24
VOC 28 0.56 0.52
HAP 11.5 0.23 0.12
CO2 2,909 5,182 1,727
Ozone Not measured Not measured 0.0019*
* at the UV oven exhaust
Similarly, Table 38 shows the substantial additional energy cost for the controlled
water-borne system to achieve the same low level of emissions as the UV installation.
Table 38. Total industrial installation and utility energy use (million BTU/billion cans)
(Golden, 2005)
Process
Emissions Water-borne
Thermal,
uncontrolled
Water-borne
Thermal +
incineration
UV curing
Electricity 16 300 19 500 15 900
Natural gas 23 900 60 100 0
Total 40 200 79 600 15 900
Applicability
When using the right pre-treatment and primer system, any metallic object can be
coated with a wet chemical coating. Interesting about coating technique is that it is an
additional technology. Almost every company in the sector can, at any time, start to
incorporate coatings in their products or processes. Due to the existence of job coating
companies, even the investment of coating technology and knowledge is not
necessary.
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Changeover to U-cured coating systems requires changes to the coating application
processes. Even if coatings are applied by jobcoaters, tests and selection procedures
need to be performed in advance. This together with the often required selection of a
new supplier (jobcoater) increases the threshold for this application. Moreover
transferring the environmental impact of the process towards supplier companies can
tend to reduce their environmental requirements.
Certain production parameters need adaptation to get the highest performance with
the coated products. Employees need to be aware that products have a coating and
pre-treatment of the tool in production could need an adaptation.
Economics
In general a higher added value due to the introduction of new surface functions can
considerably increase competitiveness. It has been estimated that a 5% increase in
added value due to innovative surface technology compensates a 20% lower cost of
manufacturing in foreign countries. The added value of using the appropriate surface
treatment technology is estimated at ca. 3-7% (Stenzel and Rehfeld, 2011).
Powder coatings cured with UV are 100% solids, while liquid paints have a reduced
solid content (solvent borne paint about 40–45%, waterborne paint about 40%, higher
solids about 65%), and need viscosity adjustment generating extra handling costs.
Transfer efficiency of powders is 95%, and nearly all powder over-spray can be
recycled or reused.
As powder coatings are solvent free, lower airflow during curing is required. For wet
paint, high airflow is required for curing and volatile removal. This results in higher
energy costs.
Powder coatings are ready to use as delivered, do not require online viscosity
adjustments or testing. Higher operating efficiency. The use of powder coatings allows
closer line spacing (no solvent evaporation) with lower rejection rates, leading to a
higher operating efficiency (PCI, 2000).
Driving force for implementation
Main driving forces for implementation are:
- More efficient energy use;
- Higher quality products with additional functionality;
- Added value products;
- Faster throughput time with UV coatings.
Reference organizations
Ridley bikes - coating on metallic frames.
http://www.ridley-bikes.com/be/en
Trislot. Trislot’s focus is on providing highly specialized filter elements and reactor
internals to key players in various industries - coating on metallic filter elements.
http://www.trislot.be
Art Casting – protective coatings on Si-bronze.
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http://www.artcasting.be
Reference literature CCI Thermal, 2015, The Benefits of Infrared in Finishing and Curing, available online
at:
http://www.ccithermal.com/about-infrared-heat/the-benefits-of-infrared-in-finishing-
and-curing.php, last accessed on 29th May 2015.
Geldermann, J., Treitz, M., 2008, Quantifying Eco-Efficiency with Multi-Criteria
Analysis. Research Paper Nr. 5 Göttingen, Oktober 2008, available online at:
Golden, R., 2005. Low-Emission Technologies: A Path to Greener Industry. RADTECH
Report, May/June 2005.
IST, 2015, Hot air infrared drying system HID. IST Metz GmbH, available online at:
http://www.ist-uv.com/fileadmin/user_upload/UV-Technologie/F118_04-08_gb.pdf,
last accessed on 29th May 2015.
PNEAC, 2015, Printers’ National Environmental Assistance Centre, available online at:
http://www.p,eac.org, last accessed on 29th May 2015.
PCI, 2000, UV-Curable Powder Coatings: Benefits and Performance, Paint & Coatings
Industry, available online at:
http://www.pcimag.com, last accessed on 29th May 2015.
Sutter, J., Dudler, V., Meuwly, R., 2011. Packaging Materials. Printing inks for food
packaging, composition and properties of printing inks. International Life Sciences
Institute, ISLI Europe, Report Series.
Stenzel, V., Rehfeld, N., 2011. Functional Coatings. European Coatings Tech Files.
Vincentz Network, Hanover.
UV Process, 2015, UV LED cure- all linear, available online at:
http://www.uvprocess.com/product.asp?code=UV+LED+++C, last accessed on 29th
May 2015.
Wall, C., Richards, B., Bradlee, C., 2004. The Ecological and Economic Benefits of UV
Curing Technology RadTech Report 2004, In Quantifying Eco-Efficiency with Multi-
Criteria Analysis, Geldermann J., Treitz M, available online at:
https://www.uni-
goettingen.de/de/document/download/03272d0c4424097d5a314b06f02426d1.pdf/08
_10_Quantifying%20Eco-Efficiency.pdf, last accessed on 29th May 2015.
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2.4. Concurrent engineering and product design as Best
environmental management practice
2.4.1. Remanufacturing of high value components
Description
Remanufacturing is an industrial process whereby used products are restored to useful
life. Remanufacturing involves a series of steps returning a product or product part to
like-new state / performance performance, with a similar or extended warranty to
match. Remanufacturing differs from recycling. As with all product reuse options,
remanufacturing involves preserving the whole form of products. Recycling requires
the destruction of products to its component materials so they can be melted, smelted
or reprocessed into new forms. These new forms can be the same products (called
closed loop recycling) or new ones (open loop recycling) (CRR, 2015). Furthermore,
remanufacturing differs from reuse whereby whole products or product parts are used
again in one piece (Figure 83).
Raw material processing
Manufacture Use End of life
Waste
Recycle
Reuse
Remanufacturing
Figure 83. Remanufacturing, restoring used products to useful life (CRR, 2013)
Materials constitute 40 to 60%of the total cost base of manufacturing firms in Europe
(McKinsey, 2015). For Fabricated Metal Products companies this means that
remanufacturing products or their components has a significant cost saving potential.
Remanufacturing of products or their components allows Fabricated Metal Products
companies to generate (new) business without transforming raw materials into new
products or components. Next to having higher direct material cost, primary
manufacturing processes are in general more labour and energy intensive than
remanufacturing processes. Remanufacturing leads to a lower material and energy
use, which results in a lower environmental impact.
There are many sectors in which remanufacturing can be applied, but sectors like the
automotive and sectors producing investment goods like heavy duty motors, pumps,
compressors, gearboxes, etc.; have the highest potential (Fraunhofer, 2013). The
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various products (in general high value components) which are remanufactured or
have a high potential to be remanufactured are for example (CRR, 2015):
- Machine tools;
- Electrical motors and compressors;
- Automatic transmissions;
- Car and truck engines and their components (compressors, pumps…);
- Air-conditioning units;
- Pumps;
- Industrial food processing equipment;
- Aerospace.
In general, remanufacturing is a series of steps of which the sequence can be different
depending on the products. The most important steps, included in almost every
remanufacturing process, are (Fraunhofer, 2013):
- Collection of products to be processed;
- Disassembly of product;
- Cleaning of parts;
- Inspection and sorting of parts;
- Reconditioning of parts and/or replacement by new parts;
- Product reassembly;
- Final testing.
Figure 84 presents the relation between the various remanufacturing steps and the
preferable product properties. Although it is important to have the whole
remanufacturing process in mind when designing products for remanufacturing, this
matrix can be used as a design tool by means of which the designer can easily find out
what properties are needed for the different steps (Gray, C. and M. Charter, 2007).
Figure 84. The RemPro-matrix showing the relationship between the preferable
product properties and the generic remanufacturing process steps (Sundin, 2004)
Easy disassembly results in shorter disassembly times and higher recovery rate of
intact parts. Design for disassembly is therefore an important component of design for
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remanufacturing. Where remanufacturing is suitable, design for remanufacturing may
improve the efficiency of remanufacturing by:
- Reducing disassembly and reassembly times and thereby also reducing
inspection/evaluation time and costs. Standardisation of securing methods like
screw types and threading, seals, etc. For example: The BMA ergonomic chair
is assembled and disassembled on the same production line in 16 min. BMA
applies a take back business model which provides the customer an incentive
to return the chairs (Figure 85).
Figure 85. BMA assembly – disassembly line (BMA-ergonomics, 2015)
- Specifying materials and forms appropriate for repetitive remanufacture. Steel
alloys are in general very good and sustainable material with high potential for
remanufacturing: materials wear, hardness, form stability, possibility to clean
and corrosion protection.
- Building mechanisms into the product or component to ensure the return of
cores. For example: Separating the wear component from the structural
components is a successful approach (Gray C. and M. Charter, 2007).
On the technological side, the product design and the process of remanufacturing
should result in a perfect valuable product and meet all the required technical
specifications required of the original part/product. Therefore, each of the
remanufacturing process steps will require a case-specific investigation and the
process sequence steps might differ from the classic production process (Butzer and
Seifert, 2013):
- Collection: Reverse logistics, sorting and batching;
- Disassembly: Optimization of disassembling, tooling, automation and modular
processes;
- Inspection: Product/component integrity;
- Cleaning & Storage: Sand blasting and degreasing;
- Remediation: Welding, applying new coatings, replacement parts and building
packages;
- Reassembling: Assembling;
- Testing: functionality and integrity.
Achieved environmental benefits
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Remanufacturing of high value components is a resource efficient process. By
remanufacturing high value products or components the embodied energy can be
preserved and production waste can be reduced. These two aspects have an
immediate impact on the CO2 emissions related to the products. Sundin (2004)
indicates that, from a natural resource perspective, remanufacturing is preferable to
new manufacturing. With remanufacturing the initial efforts to shape the product parts
(usually the most energy-intensive such as melting, casting etc.) are salvaged.
Furthermore, it is found that it is environmentally and economically beneficial to have
products designed for remanufacturing.
Case studies clearly indicate the environmental and economic benefits of
remanufacturing of high value components in the metal fabrication sector.
At Caterpillar, within the UK-based operation for EMEA, remanufacturing was already
initiated since 1972. In total 43 million tonnes of core materials were reused, leading
to up to 90% cost savings over new materials and to ca. 52 million tonnes of CO2
avoided (Walsh, 2013; Caterpillar, 2015).
A reduction of CO2 emissions of 30% to over 50% are reported for typical automotive
parts compared to new products (Fraunhofer, 2013).
An example of remanufacturing starters and generators indicated annual savings
(compared to the production of new components) of ca. 88% energy (~ 85,000 MWh)
and significant amounts of metals (e.g. 200 ton copper and 350 ton aluminium)
(Schlosser, 2011).
Appropriate environmental indicators
Appropriate environmental indicators are:
- The amount of the remanufactured components per product sold
(weight/products);
- The percentage of the products sold without remanufactured components out
of the products sold with remanufactured components.
The embodied energy that can be preserved or the amount of CO2 emissions reduced,
e.g. relative reduction compared to new products, %. The embodied energy can be
calculated (often supported by external knowledge or competence centres) comparing
the embodies energy or semi-quantitative environmental impact of new versus
remanufactured components. Having this investigation performed provides an insight
in the impact. This is a quantitative approach.
Cross-media effects
Remanufacturing case studies show that the companies performing remanufacturing
often have problems with material flows, use of space and high inventory levels. This
is often due to the uncertainties in the quality and the number of used products
suitable for remanufacturing. To overcome these problems, the remanufacturers need
to achieve a better control over the product’s design and use phase, i.e. the life cycle
phases that precede the remanufacturing process. This lead to additional space
requirements (e.g. warehouses) (Sundin, 2004).
Operational data
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Case study: ZF Belgium (BE) – truck transmission refurbishment
At ZF Services Belgium, specialized in truck transmission refurbishment, in total over
1,700 transmissions types exist. Creating stock for each of those types appeared not
to be cost effective. Manufacturing new parts was not possible to keep on time
delivery. With the recuperated parts approximately 20 standard packages are
composed. Those packages are composed in such a manner that they allow to
refurbish the over 1,700 varieties of transmissions in a short time. This results in a
service level of 100% within 24 hours instead of the 7% before. Meanwhile the total
number of varieties increased to 3,000, without impacting the service level. A cost
reduction of 20% is realized (Industrie - Technisch & management, 2011).
Case study Portal Power (UK) – portal frame buildings
The main activities of Portal Power, are the
design and erection of portal frame buildings.
Over 40% of their 2,000 – 3,000 tonnes
annual throughput is pre-used portal frame
buildings. Portal Power oversees the whole
process from deconstruction, through any
modification to final erection in a new
location. After deconstruction, Portal Power
stores the steel while waiting for a buyer.
When a customer is found, Portal Power can
modify the building, adding value to their
business (Allwood, J.M. et al, 2012 and Portal
Power, 2015; Figure 86).
Figure 86. Steel waiting for a buyer at the Portal Power plant (Allwood, J.M. et al,
2012 and Portal Power, 2015)
Case study Rype Office (UK) – office furniture – three business models
Rype Office (Figure 87), offers three furniture options for customers: New, remade or
refreshed, each appealing to different client preferences and openness to new
business models and remanufactured products.
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Figure 87. Rype Office offering (Rype Office, 2015)
For customers who desire brand new furniture, products can either be purchased
outright with the option of a buy-back offer, or leased for a monthly fee. Both allow
Rype Office to recover the furniture for remanufacturing at the end of its first life,
while saving customers money. The furniture offered by Rype Office in this model has
been chosen for its quality and ability to be remanufactured, reducing the cost to
renew it.
Applicability
Although there is a large variety in products which can be remanufactured, it works
best for the Fabricated Metal Products sector if the products are of high value,
complex and durable.
Areas where remanufacturing is successfully applied or has a high potential to be
applied are (Fraunhofer, 2013):
- Automotive industry. Automotive parts represents by far the largest
opportunity for remanufacturing. Although in Europe the large variety of
products makes refurbishment a challenge;
- Investment goods (heavy duty motors, pumps, compressors, gearboxes, etc.).
Especially investment goods with high material content (weight, volume and
price) and large embodied energy (casting parts, parts with complex forms,
parts with expensive materials, etc.) are very suitable for remanufacturing.
Important barriers for implementing remanufacturing in the sector are existing
regulation and standards dealing with “as new” products, the general market focus on
the quantity and recycling of products and customer trust (quality, warranty and
regulations).
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Remanufacturing has a role in enabling extended producer responsibility. But
remanufacturing is under threat from low cost imports of improving quality goods from
abroad. Perception of remanufactured goods as 'second-class' can limit sales growth
in, e.g. fashion-oriented, lifestyle or status products: cars, white goods, attire. Even
business to business transactions suffer without strong standards for the
remanufacturing process. Remanufacturing has the potential for even greater
contribution to sustainable consumption, and there are steps that all stakeholders can
take to enable this. A starting point is elimination of legal impediments such as denial
of access to manufacturer design information, banning of remanufactured components
in new goods, and redefinition of what constitutes waste. Removal of these would
increase competition and force evolution of improved services, including
remanufacturing (CRR, 2015).
Investment goods have the largest potential for remanufacturing. Logistics and
technical feasibility to remanufacture the products play an important role. Therefore
the product design has a large impact on the remanufacturing efficiency.
Remanufacturing leads, in most cases to additional space requirements, to avoid this
smart stock solutions or product combinations can be an option (see ZF Belgium
case).
Economics
The implementation of remanufacturing of high value components can lead to cost
savings both for the organizations and the consumers. Depending on the product and
the intrinsic value of the parts, the savings for consumers can go up to 90%. From the
perspective of the companies, remanufacturing leads to lower costs compared to
manufacturing from raw materials. Organizational changes can even further reduce
costs (ZF case 20% reduction) and in general the margin on remanufactured parts are
higher compared to new parts (Fraunhofer, 2013).
Remanufacture can offer a business model for sustainable prosperity, with reputed
double profit margins alongside a significant reduction in carbon emissions (OHL,
2004) and 15% of the energy required in manufacture (Steinhilper, 2006).
A successful remanufacturing strategy (Figure 88) implies often new business models
(green label, product guarantee, involvement of distribution channels, leasing, take
back systems, etc.), adjusted product design (modular, etc.) and performant
manufacturing system (i.e. short delivery times, effective logistic loops, building
packages dealing with complexity, etc.) (Sirris/Agoria, 2015).
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Figure 88: Remanufacturing requires different aspects in the “three basic components
of industry” to be balanced (Sirris/Agoria, 2015)
Depending on the sector, remanufacturing can have an impact on the EBITDA
(Earnings before interest, tax, depreciation and amortisation and is a profit metric
measured by companies in. It does not account for the additional capital expense
required to establish remanufacturing, which would comprise the space and equipment
to disassemble products and cleaning and refurbishment equipment) and number of
jobs (Figure 89). Different Fabricated Metal Products companies are active in the
machinery, equipment and transport equipment.
Figure 89. Impact of full remanufacturing on EBITDA and jobs in four sectors in the UK
(Lavery et al, 2013)
Driving force for implementation
Remanufacturing of high value components in the sector is a practical example of the
circular economy, leading to an extended product-service. The economic (cost
reduction and increased revenue) and environmental benefits (material and energy
efficient process leading to reduction in CO2 emissions) are the main driving forces for
implementation.
Reference organizations
ZF Services Belgium:
http://www.zf.com/sso/content/en/import/zf_services_belgium/zf_services_belgium_n
v_sa/wie_zijn_wij/_ZF_Belgien_____een_vleugje_geschiedenis_______1.html
Punch Power Train. Punch Powertrain offers a complete portfolio of powertrain
solutions for the most popular passenger car segments.
http://www.punchpowertrain.com/en.
Caterpillar UK:
http://www.caterpillar.com/en/company/corp-overview/global-footprint/eame/uk.html
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ABC Diesel: http://www.abcdiesel.be/en/index
Rype Office. offers three furniture options for customers: New, Remade or Refreshed,
each appealing to different client preferences and openness to new business models
and remanufactured products. http://www.rypeoffice.com
Trumetic Ltd (UK): Trumetic Refrigeration Compressor Re-Manufacturing services
offers a wide range of Refrigeration Compressor Servicing solutions for applications.
http://www.trumeticlimited.co.uk/remanufacturing.php
Reference literature
Allwood, J.M., Cullen, J.M., Carruth, M.A., Cooper, D.R., McBrien, M., Milford, R.L.,
Moynihan, M., Patel, A.C.H, 2012, Sustainable materials: with both eyes open. UIT,
Cambridge. ISBN 978-1-906860-05-9, available online at:
http://www.withbotheyesopen.com/, last accessed on 7th September, 2015.
BMA-ergonomics, 2015, Duurzame kantoorstoel, available online at:
http://www.bma-ergonomics.be/duurzaam, last accessed on 7th September, 2015.
Butzer S., Seifert S., Fraunhofer, 2013. Remanufacturing - Market and Technology
Trends, Business Opportunities and Benefits. Sustainable Industry Forum 2013.
Caterpillar, 2015, Remanufacturing, available online at:
http://www.caterpillar.com/en/company/sustainability/remanufacturing.html, last
accessed on 7th September, 2015.
Ellen Macarthur Foundation, 2014, Rype Office, available online at:
http://www.ellenmacarthurfoundation.org/case_studies/rype-office, last accessed on
7th September 2015.
Gray C. and M. Charter, 2007, Remanufacturing and Product Design Designing for the
7th Generation, The Centre for Sustainable Design University College for the Creative
Arts, Farnham, UK, available online at:
http://cfsd.org.uk/Remanufacturing%20and%20Product%20Design.pdf, last accessed
on 7th September, 2015.
Industrie – technisch & Management, 2011. ITM Industrie award “Best Practice in
Manufacturing”, available online at:
http://acties.industrie-technisch-management.knack.be/acties/industrie-technisch-
management/itmawards/itm_awards_nl_lrf/images/2011/ITM_AWARD_2011_NL.pdf,
last accessed on 7th September, 2015.
Lavery G., Pennell N., Brown S., Evans S., 2013, The next manufacturing revolution:
non-labour resource productivity and its potential for UK manufacturing. 164p,
available online at:
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http://laverypennell.com/wp-content/uploads/2013/09/Next-Manufacturing-
Revolution-full-report.pdf, last accessed on 15th September 2015.
McKinsey, 2015, Europe’s circular-economy opportunity, Adopting circular-economy
principles could not only benefit Europe environmentally and socially but could also
generate a net economic benefit of € 1.8 trillion by 2030, available online at:
http://www.mckinsey.com/insights/sustainability/europes_circular-
economy_opportunity, last accessed on 7th September 2015.
Portal Power, 2015, Green steel buildings, available online at: http://www.portal-
power.co.uk/environmental-steel-buildings.php, last accessed on 7th September 2015.
Rype Office, 2015, Lower cost quality office furniture, available online at:
http://www.rypeoffice.com/, last accessed on 7th September 2015.
Schlosser, 2011, Energy and Resource Efficiency in Production, Seminar “Produceer
met minder energie”, Zwijnaarde, 2011, available online at:
http://www.slideshare.net/sirris_be/produceer-met-minder-energie-energy-and-
ressource-efficiency-in-production-ralf-schlosser
Sirris & Agoria, 2015, Masterplan Innovation for the technology industry.
Sundin, 2004, Product and Process Design for Successful Remanufacturing. Linköping
Studies in Science and Technology, Linköpings Universitet, Sweden, available online
at:
http://www.diva-portal.org/smash/get/diva2:20932/FULLTEXT01.pdf, last accessed on
7th September, 2015.
Walsh B., 2013, Remanufacturing in Europe – Business Cases, Sustainable Industry
Forum 2013 "Treating Waste as a Resource", Brussels, 27 May 2013.
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2.4.2. Co-design and open innovation with downstream partners to reduce
environmental impact during product life cycle
Description
Using direct input and feedback from customers and end-users in the design and
engineering phase provides opportunities for environmental friendly solutions and
designs. Making use of a growing group of experts from various sectors offers the
chance to capture new insights and new break through ideas. In contrast with open
innovation, where research and development is performed in-house and no or little
external knowledge is used, open innovation makes use of external partners to
achieve research and development. With open innovation the boundaries with the
surrounding environment of the company are easily crossed and own ideas are
brought to the market (Figure 90).
Figure 90. Closed vs. open innovation (Chesbrough, 2003)
Close collaboration between companies in the sector and downstream (end-)users
provides in depth insight in design requirements. The open innovation creates a
platform for an iterative design approach allowing fast validation of design ideas and
concepts. This can speed up the design and engineering process while safeguarding
the customer expectations and market acceptance. The process can capture new
break-through ideas from (experts) all over the world and can lead to a faster time to
market. Open innovation also makes optimal use of available knowledge and expertise
inside and outside the company.
Co-engineering, co-design and open innovation exist in a large variety of actions, i.e.
from a single brainstorm session with limited number of stakeholders to a full process
of designing, engineering, validation up to marketing of newly developed products. In
order to implement co-design and open innovation with (end-)users, controlling the
risks and setting up processes and methods for collaboration with clear rules for all
partners is key. Clear rules need to be defined, understood and acknowledged by all
partners involved in the open innovation. Benefits for all partners have to be mutually
recognized as well. Often third party process guidance is used in order to control the
risks.
Closed
innovation Open
innovation
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Strategies for open innovation in small firms (SME’s) are (Vanhaverbeke et al 2012):
- Vision: Frequently, a (radically) new vision of entrepreneurs or managers is the
starting point for the business model of SMEs;
- The network of partners: Common in all cases is that the SMEs establish a
network of external partners. Partners may be technology partners such as
universities, research labs, or other companies, but in most cases these are not
the most important partners in the network. The size of the network is
determined by the type of products or services the SME wants to launch;
- Networks of partners have to be managed as well, but the type of management
differs from the internal management of a firm. A network of partners is only
viable when each partner is better off compared to not participating in the
network;
- Building strong ties to cope with environmental and relational risks. The biggest
challenge in an open innovation network is the market and technological risk
on the one hand and the relational risk on the other hand. The glue of an open
innovation network is the personal tie between a few key managers and actors;
- Dependence on partners’ intellectual property (IP). Low-tech SMEs can rely on
others’ IP, or they co-develop technological innovations. Most often the small
firms have negotiated technology agreements such as licensing deals with their
partners;
- A stepwise approach. SMEs change their business model in a stepwise way. In
most cases, companies begin with a (radically) new product or service, but this
is only a start. There are several reasons why open innovation is a never-
ending process for SMEs;
- The benefits and cost of relational capital. Relational capital plays a central role
in developing an open innovation based business model. The competitive
strength of the SMEs is no longer (only) related to its internal competencies,
but (also) to its network of relationships. After some years, an SME has a large
network of companies upon which it can rely.
Achieved environmental benefits
Co-design and open innovation in the Fabricated Metal Products sector provides the
possibility to set up collaborations between small local SME’s and large, globally
operating companies. It will furthermore incentivize the Design for Environment (DfE)
strategy by finding ways to create benefits for all involved partners while reducing the
overall environmental impact. Achieved environmental benefits for the companies in
the sector can be e.g. a reduced weight of the manufactured product, reduction of
waste produced during manufacturing and/or disassembling, reduction of resource use
and emissions.
Appropriate environmental indicators
By the nature of the activity, co-design and open innovation acts on the companies
(senior) management level. This means that key decisions can have major impacts on
environmental impact and on economic impact. This makes clear the a generic
environmental indicator measuring the impact of open innovation is impossible to
define. On the other hand, the importance of environmental impact that the
companies sets as part of their vision and strategy defines the potential impact.
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Indicators for measuring performance of companies using co-design and open
innovation depend on the production processes and materials, but in general this
indicators give an overall view on how companies are doing:
- kg raw material used per produced unit;
- total energy use per produced unit;
- kg waste produced per year or per product;
- % of the products which complain to the quality standards.
A key indicator is to have a set of environmental impact goals set when co-design and
open innovation is set up. Furthermore those goals can be translated to product
requirements in close collaboration with the stakeholders. Often design requirements
and features are trade-offs that can be evaluated using LCA. Depending on the
product or service provided the environmental impact can be measured as resource or
energy effectively (e.g. weight of resources used to provide specific functionality or
service).
Cross-media effects
Efficiently controlling the open innovation process or the co-design process is a key
factor to prevent overhead costs and efforts to offset the envisaged benefits.
Existing open innovation and co-design initiatives are not necessarily focussing on a
reduction of the environmental footprint. The methods applied can in this case
possibly lead to a higher environmental impact. Therefore, the focus and scope of the
innovation process need to be controlled throughout the entire process in order to
avoid negative cross-media effects.
Operational data
The operational condition largely depends on the size of the co-design or open
innovation project. Below a few examples of existing co-design and open innovation
processes in the sector are given.
Case study: ConXtech (US) - Novel joining technique to improve deconstruction of
buildings
Deconstruction of building with bolted structural elements results in a loss of re-use
potential due to inability to disassemble economically the joints between the metal
components like I-beams. The current practice is that those joints are cut and the
remaining steel scrap is recycled. Novel joining techniques could only be designed by
in depth knowledge and collaboration with building and assembly actors.
ConXtech structures are manufactured in highly automated factories utilizing BIM,
CAD/CAM, robotics, CNC machining and other technologies. Although these
technologies have been employed in the automotive, aerospace and other industries
for decades, the construction industry has been particularly slow to innovate or adopt
technology for a variety of reasons. Now, as the world begins to recognize the value of
building more sustainably, “technology” is the key to cost control and quality, and
enables unprecedented efficiencies in the use of materials, time and energy in the
built environment. ConX structures are typically lighter and assembled 2 to 4 times
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faster than conventional steel or concrete structures. Using the ConX System typically
results in cutting total tonnage, eliminating waste in field work, and reducing risk with
a stronger, safer structural system and reduce on site equipment usage
(http://www.conxtech.com).
Figure 91. The ConX® System (Cradle to Cradle Certified Products Registry, 2014)
Similar projects: Quicon, ATLSS, ConXtech and Girder Clamps.
Case study: General Electric (world)- Open innovation and micro-manufacturing
GE's original idea for open innovation and a micro-manufacturing facility came from
the company's first crowdsourcing project to create a better jet engine bracket. In
June 2013, the company held a contest in partnership with GrabCAD, an open
engineering community called "3D printing design quest." GE released their original
design for the titanium jet engine bracket and invited the public to riff off of it to
create a lighter version that would be 3D printed. Over six weeks, more than
700 entries from 57 countries came in. The winner was a 21-year-old PhD student in
Indonesia, who reduced the weight of the bracket by 84%. This case indicated not
only that open innovation can work, but part of the reason why it works is thanks to
the process of tapping into a very different group of people from the people who are
normally thinking about the engineering challenges (TechRepublic, 2015).
Case study Curana (BE) - Design and innovation management
Curana is a worldwide trendsetter and manufacturer of extraordinary bike equipment
and bike accessories. The design and innovation management at Curana follows a
structured procedure (http://www.curana.com):
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- Step 1: Exploration – Monitoring social changes, fashion trends, technology
developments, customer needs, brands research, value chain analysis,
participation in learning networks.
- Step 2: Design – Creative sessions to generate ideas, handmade models of the
new concepts, incorporation of innovative technologies for a simpler and
cheaper assembly, identification of the right technology and materials,
synergies with production partners and knowledge centres.
- Step 3: Promotion – Interactive concept presentations to clients demonstrating
solutions to problems, listening to clients’ feedback, good efforts in brochures
and packaging, image building and creation of a corporate identity (innovation
power), international design awards.
- Step 4: Realization – Development of high-end 3D model of the concept in
collaboration with engineering partner, virtual verification with knowledge
partners, rapid prototyping managing networks of external innovation
partners.
Applicability
Since co-design and open innovation exists in a large variety of actions, it can be
applied in both small and large companies in the Fabricated Metal Products sector.
Crowdsource design contests can be a stepping stone to open innovation.
For SMEs this can illustrated by the Curana’s approach, where different steps are
applied (see operational data).
Economics
Setting up and coordinating the process of co-design and open innovation represent a
cost, depending on the size of the actions. Furthermore, controlling the risks related to
innovation during the entire processes has to be taken into account. The Business
development and approaching new markets represent and additional cost as well.
Illustration of the economic impact of the open innovation at Curana is shown below
(Figure 92).
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Figure 92: Curana’s turnover and profit in relation to the bicycle production (Bosch,
2010)
Driving force for implementation
The main driving forces for implementing co-design or open innovation in the company
in the Fabricated Metal Products sector are:
- Time to market reduction;
- Search for break-through innovations;
- Search for new strategic partnerships;
- Improvement of the market position through innovations;
- Increase of innovation capabilities of the company;
- Impact on the entire life cycle and environmental impact of a product.
Reference organizations
Holst Centre is an independent R&D centre that develops technologies for wireless
autonomous sensor technologies and flexible electronics, in an open innovation setting
and in dedicated research trajectories (http://www.holstcentre.com/).
ConXtech Inc. is a privately-held construction technology company in Pleasanton, CA.
ConX is a mass-customizable, modular, prefabricated structural steel building system
for high density residential, commercial, healthcare and institutional structures, as
well as industrial pipe rack. The ConX System is the first Cradle to Cradle Certified
steel building system in the world. (http://www.conxtech.com/company/history/).
Curana is a worldwide trendsetter and manufacturer of extraordinary bike equipment
and bike accessories (http://www.curana.com/).
Metal Valley. When it comes to design, engineering and production, we have to move
with the changes in the market. This is why Metal Valley Netherlands offers
partnerships with entrepreneurs, specialists and students. The only way to create new
opportunities for the entire metal sector is through open innovation.
(http://www.metalvalley.eu/en/innovation).
The Open Manufacturing Campus aims to be not only a physical place where
innovative manufacturing companies can establish themselves, but also a virtual Open
Manufacturing Community that reaches far beyond the boundaries of the physical
campus (http://openmanufacturingcampus.com).
Corda Campus. This is the leading tech campus in the heart of the EUREGIO. It is a
motivating business community for countless innovative businesses and start-ups.
Corda Campus is the place to be for fruitful partnerships and a fascinating exchange of
knowledge and ideas. (http://www.cordacampus.com/nl/corda-
campus/campus/corda-concept/open-innovatie).
Jaga Open innovation for radiators:
http://www.sciencebusiness.net/eif/documents/Open-innovation-in-SMEs.pdf.
Reference literature
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Bosch S., 2010, Curana BVBA: managing open innovation for growth in SMEs. Esade
Business School. Paper, 20p, available online at:
http://www.sciencebusiness.net/eif/documents/Managing_open_innovation_for_growt
h_in_SMEs.PDF, last accessed on 29th September 2015.
Chesbrough, 2013, Open Innovation: The New Imperative for Creating and Profiting
from Technology. Boston, Harvard Business School Press, ISBN: 1-57851-837-7.
Cradle to Cradle Certified™ Products Registry, 2014, available online at:
http://www.c2ccertified.org/products/scorecard/conxl_and_conxr, last accessed on
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